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Lexm 4 \rk 



4069-XXX 



Edition: May 2000 

The following paragraph does not apply to any country where such provisions are 
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS 
PUBLICATION "AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR 
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF 
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not 
allow disclaimer of express or implied warranties in certain transactions; therefore, this 
statement may not apply to you. 

This publication could include technical inaccuracies or typographical errors. Changes are 
periodically made to the information herein; these changes will be incorporated in later 
editions. Improvements or changes in the products or the programs described may be 
made at any time. 

A form for reader's comments is provided at the back of this publication. If the form has 
been removed, comments may be addressed to Lexmark International, Inc., Department 
D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark 
may use or distribute any of the information you supply in any way it believes appropriate 
without incurring any obligation to you. You can purchase additional copies of publications 
related to this product by calling 1-800-553-9727. In other countries, contact your point of 
purchase. 

Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United 
States and/or other countries. 

Other trademarks are the property of their respective owners. 

© Copyright Lexmark International, Inc. 1999, 2000. 
All rights reserved. 

UNITED STATES GOVERNMENT RESTRICTED RIGHTS 

This software and documentation are provided with RESTRICTED RIGHTS. Use, 
duplication or disclosure by the Government is subject to restrictions as set forth in 
subparagraph (c)(1 )(ii) of the Rights in Technical Data and Computer Software clause at 
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., 
Lexington, KY 40550. 



4069-XXX 

Contents 



Notices and Safety Information ix 

Laser Notices ix 

Safety Information xvii 

Preface xxii 

General Information 1-1 

Options 1-3 

Maintenance Approach 1-4 

Tools Required For Service 1-4 

Acronyms 1-5 

Diagnostic Information 2-1 

Start 2-1 

Service Error Codes 2-2 

User Status Messages 2-12 

User Error Messages 2-16 

Power-On Self Test (POST) 2-24 

Symptom Tables 2-25 

Service Checks 2-28 

Charge Roll Service Check 2-29 

Cover Open Switch/Cable Service Check 2-31 

Dead Machine Service Check 2-32 

Duplex Option Service Check 2-35 

Envelope Feeder Option Service Check 2-38 

Erase Lamp Service Check (0 1 0/2 1 2/4 14/61 6/3 1v) 2-45 

Fan Service Check 2-46 

Fuser Service Check 2-47 

Fuser Solenoid Service Check 2-51 

Input Sensor Service Check 2-52 

Input Tray(s) Option Service Check 2-53 

High Capacity Feeder Input Tray Service Check 2-56 

Main Drive Service Check 2-69 

Operator Panel Service Check 2-70 

Options Service Check 2-72 

Output Bin Sensor Standard Tray Service Check 2-74 

Output Expander Service Check 2-75 

High-Capacity Output Stacker Service Check 2-80 

5-Bin Mailbox Service Check 2-83 

Paper Feed Service Check 2-89 

Parallel Port Service Check 2-91 



Contents iii 



4069-XXX 

Printhead Service Check 2-92 

Print Quality Service Check 2-93 

Smart Cartridge Service Check 2-1 06 

Serial Port Service Check 2-107 

Toner Sensor Service Check 2-107 

Transfer Roll Service Check 2-1 08 

Diagnostic Aids 3-1 

Diagnostic Mode 3-1 

Device Tests 3-2 

Quick Disk Test 3-2 

Disk Test/Clean 3-2 

Flash Test 3-3 

Disabling Download Emulations 3-3 

Duplex Tests 3-4 

Duplex Quick Test 3-4 

Duplex Sensor Test 3-5 

Duplex Motor Test 3-5 

Duplex Feed 1 Test 3-7 

Duplex Feed 2 Test 3-7 

Error Log 3-8 

Viewing the Error Log 3-8 

Clearing the Error Log 3-8 

Hardware Tests 3-9 

LCD Test 3-9 

Button Test 3-9 

SDRAM Memory Test 3-10 

ROM Memory Test 3-10 

Parallel Wrap Test 3-11 

Serial Wrap Test 3-12 

Input Tray Tests 3-14 

Input Tray Feed Test 3-14 

Input Tray Sensor Test 3-14 

Output Bin Test - Standard Bin 3-15 

Output Bin Feed Test 3-15 

Output Bin Sensor Test 3-16 

Output Bin X Sensor Test 3-16 

Base Sensor Test 3-17 

5-Bin Mailbox Diverter Test 3-18 

Print Registration 3-19 

Printer Setup 3-20 

Setting the Page Count 3-20 

Viewing the Permanent Page Count 3-20 

iv Service Manual 



4069-XXX 

Maintenance Page Count 3-21 

Setting Configuration ID 3-21 

Restore EP Factory Defaults 3-22 

Print Tests 3-23 

Print Quality Test Pages 3-24 

Printing Menu Settings Page 3-25 

Autocompensator Operation 3-26 

Autoconnect System, Paper Tray Options, Envelope Feeder and 

Output Expander Operations 3-27 

Fuser Operation 3-29 

Paper Feed Jams 3-31 

Repair Information 4-1 

Handling ESD-Sensitive Parts 4-1 

Adjustment Procedures 4-2 

Duplex Motor Drive Belts 4-2 

Fuser Solenoid Adjustment 4-3 

Gap Adjustment 4-3 

Printhead Assembly Adjustment 4-4 

Paper Alignment Assembly Adjustment 4-5 

Screw Identification Table 4-7 

Removal Procedures 4-12 

Covers 4-12 

Center Pan Assembly 4-16 

Controller Board 4-17 

Developer Drive Assembly 4-18 

Duplex Board 4-19 

Duplex Front Cover Assembly 4-19 

Duplex Front Cover Door 4-19 

Duplex Motor 4-20 

Engine Board 4-21 

EP Frame Assembly 4-21 

Fans 4-22 

Fuser 4-24 

Fuser Board (Hot Roll) 4-25 

Fuser Cover (Hot Roll) 4-26 

Fuser Detack Fingers (Hot Roll) 4-26 

Fuser Detack Housing Assembly (Hot Roll) 4-27 

Fuser Transfer Plate (Hot Roll) 4-28 

Fuser Envelope Conditioner Solenoid (Hot Roll) 4-29 

Fuser Narrow Media Sensor/Flag Assembly (Hot Roll) . . 4-30 

Fuser Exit Sensor Flag Assembly 4-30 

Fuser Lamp (Hot Roll) 4-30 



Contents v 



4069-XXX 

Fuser Lower Exit Guide Assembly (Hot Roll) 4-31 

High Voltage Power Supply 4-32 

Inner EMC Shield 4-33 

Inner Paper Deflector Assembly 4-34 

Integrated Tray Compensator Assembly 4-35 

Integrated Tray Compensator Pick Roll Assembly 4-36 

Interconnect Board Assembly 4-37 

Left Side Frame 4-39 

Low Voltage Power Supply 4-41 

Main Drive Assembly 4-42 

Main Drive Motor 4-44 

Multipurpose Tray/Lower Deflector Assembly 4-45 

Operator Panel Assembly 4-47 

Operator Panel Cable/Cover Open Switch Assembly . . . 4-48 

Optional 250/500 Paper Tray Assembly 4-49 

Outer EMC Shield 4-50 

Paper Alignment Assembly 4-51 

Paper Input Sensor 4-52 

Paper Size Sensing Board 4-53 

Pick Roll 4-53 

Printhead 4-54 

Redrive Assembly 4-55 

Right Side Frame 4-56 

Smart Cartridge Contacts 4-57 

Toner Sensor 4-58 

Transfer Roll Assembly 4-59 

Upper Paper Deflector Assembly 4-59 

Upper Front Cover Hinge Assembly 4-60 

Upper Front Cover Interlock Switch Assembly 4-61 

Connector Locations 5-1 

Low Voltage Power Supply 5-1 

High Voltage Power Supply 5-3 

Engine Board 5-4 

Fuser Board 5-11 

Interconnect Board 5-12 

Envelope Option Board 5-15 

Duplex Option Board 5-17 

Autoconnect - Top 5-19 

Output Expander Control Board 5-20 

High-Capacity Output Stacker Board 5-22 

Preventive Maintenance 6-1 

Safety Inspection Guide 6-1 

vi Service Manual 



4069-XXX 

Lubrication Specifications 6-1 

Scheduled Maintenance 6-2 

Parts Catalog 7-1 

How To Use This Parts Catalog 7-1 

Printer Serial Label 7-2 

Assembly 1 : Covers 7-4 

Assembly 2: Frame 7-8 

Assembly 3: Printhead 7-12 

Assembly 4: Paper Feed (Autocompensator) 7-14 

Assembly 5: Paper Feed - Multipurpose Unit 7-16 

Assembly 6: Paper Feed - Alignment 7-18 

Assembly 7: Paper Feed - Output 7-20 

Assembly 8: Integrated Paper Tray - 250 Sheet 7-22 

Assembly 9: Integrated Paper Tray - 500 Sheet 7-24 

Assembly 1 0: Main Drive 7-26 

Assembly 1 1 : Developer Drive 7-28 

Assembly 1 2: Hot Roll Fuser 7-30 

Assembly 1 3: Belt Fuser 7-34 

Assembly 14: Transfer 7-36 

Assembly 15: Charging 7-38 

Assembly 16: Electronics 7-40 

Assembly 1 7: 250 Sheet Tray 7-52 

Assembly 1 8: 500 Sheet Tray 7-56 

Assembly 1 9: Duplex 7-60 

Assembly 20: Output Expander 7-66 

Assembly 21 : Envelope Feeder 7-70 

Assembly 22: High Capacity Feeder 7-74 

Assembly 23: Kiosk - Vertical Paper Adapter 7-88 

Assembly 24: Kiosk - Horizontal Paper Adapter 7-90 

Assembly 25: High-Capacity Output Stacker 7-92 

Assembly 26: 5-Bin Mailbox 7-98 

Assembly 27: Options 7-102 

Assembly 28: Miscellaneous 7-104 



Contents vii 



4069-XXX 



viii Service Manual 



4069-XXX 



Notices and Safety Information 



Laser Notices 

The following laser notice labels may be affixed to this printer as 
shown: 



Laser Advisory Label 




CAUTION - 




ATTENTION ■ 




VORSICHT - 


JnsicHbare laserslrahlurc] 






ATTENZIONE - 




AVISO - 




CJIDADO - 


Radtaf&O laser imnsiwl qu 






■ ■ ■ 








AOVARSEL- 


Usynlig laserstraling ved fib 



ia abierta y el disposltlvo nc 



<-.'. -.loojBiKic. Eviie eicorerse a I 



as Diet aloiina rakymaitnma.119 lasersaleilyliB. Ala kalso sateBaeen. 

a' appnad ach spa: ■ ■ v.lsn 3r tarlig. 

is og sikkertteflsias brylaa Unnga aksporcetirig lor slralen. 

■-■■ ■ .:.:■■ ■■ ■■■■■ :■ . ■■■ ■ ■■■■■.-.■ : ■ ■ ../■ ■ : / ■■ 



Notices and Safety Information ix 



4069-XXX 

Class 1 Laser Statement Label 




CLASS 1 LASER PRODUCT 
LASER KLASSE 1 
LOUKAN 1 LASERLAITE 
APPAREIL A LASER DE CLASSE 1 
TO IEC 6082S 



x Service Manual 



4069-XXX 



Laser Notice 

The printer is certified in the U.S. to conform to the requirements of 
DHHS 21 CFR Subchapter J for Class I (1 ) laser products, and 
elsewhere is certified as a Class I laser product conforming to the 
requirements of IEC 60825. 

Class I laser products are not considered to be hazardous. The 
printer contains internally a Class 1Mb (3b) laser that is nominally a 5 
milliwatt gallium arsenide laser operating in the wavelength region of 
770-795 nanometers. The laser system and printer are designed so 
there is never any human access to laser radiation above a Class I 
level during normal operation, user maintenance, or prescribed 
service condition. 



Laser 

Der Drucker erfiillt gemaB amtlicher Bestatigung der USA die 
Anforderungen der Bestimmung DHHS (Department of Health and 
Human Services) 21 CFR Teil J fur Laserprodukte der Klasse I (1). 
In anderen Landern gilt der Drucker als Laserprodukt der Klasse I, 
der die Anforderungen der IEC (International Electrotechnical 
Commission) 60825 gemaB amtlicher Bestatigung erfiillt. 

Laserprodukte der Klasse I gelten als unschadlich. Im Inneren des 
Druckers befindet sich ein Laser der Klasse 1Mb (3b), bei dem es 
sich urn einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen 
der Lange 770-795 Nanometer ausstrahlt. Das Lasersystem und der 
Drucker sind so konzipiert, daf3 im Normalbetrieb, bei der Wartung 
durch den Benutzer oder bei ordnungsgemaBer Wartung durch den 
Kundendienst Laserbestrahlung, die die Klasse I ubersteigen wiirde, 
Menschen keinesfalls erreicht. 



Avis relatif a I'utilisation de laser 

Pour les Etats-Unis : cette imprimante est certifiee conforme aux 
provisions DHHS 21 CFR alinea J concernant les produits laser de 
Classe I (1). Pour les autres pays : cette imprimante repond aux 
normes IEC 60825 relatives aux produits laser de Classe I. 



Notices and Safety Information xi 



4069-XXX 

Les produits laser de Classe I sont consideres comme des produits 
non dangereux. Cette imprimante est equipee d'un laser de Classe 
1Mb (3b) (arseniure de gallium d'une puissance nominale de 5 
milliwatts) emettant sur des longueurs d'onde comprises entre 770 
et 795 nanometres. Limprimante et son systeme laser sont congus 
pour impossible, dans des conditions normales d'utilisation, 
d'entretien par I'utilisateur ou de revision, I'exposition a des 
rayonnements laser superieurs a des rayonnements de Classe I . 



Avvertenze sui prodotti laser 

Questa stampante e certificata negli Stati Uniti per essere conforme 
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di 
classe 1 ed e certificata negli altri Paesi come prodotto laser di 
classe 1 conforme ai requisiti della norma CEI 60825. 

I prodotti laser di classe non sono considerati pericolosi. La 
stampante contiene al suo interno un laser di classe 1Mb (3b) 
all'arseniuro di gallio della potenza di 5mW che opera sulla 
lunghezza d'onda compresa tra 770 e 795 nanometri. II sistema 
laser e la stampante sono stati progettati in modo tale che le 
persone a contatto con la stampante, durante il normale 
funzionamento, le operazioni di servizio o quelle di assistenza 
tecnica, non ricevano radiazioni laser superiori al livello della classe 
1. 



Avisos sobre el laser 

Se certifica que, en los EE.UU., esta impresora cumple los 
requisitos para los productos laser de Clase I (1 ) establecidos en el 
subcapftulo J de la norma CFR 21 del DHHS (Departamento de 
Sanidad y Servicios) y, en los demas pafses, reune todas las 
condiciones expuestas en la norma IEC 60825 para productos laser 
de Clase 1(1). 

Los productos laser de Clase I no se consideran peligrosos. La 
impresora contiene en su interior un laser de Clase 1Mb (3b) de 
arseniuro de galio de funcionamiento nominal a 5 milivatios en una 
longitud de onda de 770 a 795 nanometros. El sistema laser y la 
impresora estan disehados de forma que ninguna persona pueda 
verse afectada por ningun tipo de radiacion laser superior al nivel de 

xii Service Manual 



4069-XXX 

la Clase I durante su uso normal, el mantenimiento realizado por el 
usuario o cualquier otra situacion de servicio tecnico. 



Declaracao sobre Laser 

A impressora esta certificada nos E.U.A. em conformidade com os 
requisitos da regulamentagao DHHS 21 CFR Subcapftulo J para a 
Classe I (1) de produtos laser. Em outros locais, esta certificada 
como urn produto laser da Classe I, em conformidade com os 
requisitos da norma IEC 60825. 

Os produtos laser da Classe I nao sao considerados perigosos. 
Internamente, a impressora contem urn produto laser da Classe 1Mb 
(3b), designado laser de arseneto de potassio, de 5 milliwatts 
,operando numa faixa de comprimento de onda entre 770 e 795 
nanometros. O sistema e a impressora laser foram concebidos de 
forma a nunca existir qualquer possiblidade de acesso humano a 
radiagao laser superior a urn nfvel de Classe I durante a operagao 
normal, a manutengao feita pelo utilizador ou condigoes de 
assistencia prescritas. 



Laserinformatie 

De printer voldoet aan de eisen die gesteld worden aan een 
laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen 
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in 
IEC 60825. 

Laserprodukten van klasse I worden niet als ongevaarlijk 
aangemerkt. De printer is voorzien van een laser van klasse 1Mb 
(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met 
een golflengte van 770-795 nanometer. Het lasergedeelte en de 
printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of 
reparatie conform de voorschriften, nooit blootstelling mogelijk is 
aan laserstraling boven een niveau zoals voorgeschreven is voor 
klasse 1 . 



Notices and Safety Information xii 



4069-XXX 



Lasermeddelelse 

Printeren er godkendt som et Klasse l-laserprodukt, i 
overenstemmelse med kravene i IEC 60825. 

Klasse l-laserprodukter betragtes ikke som farlige. Printeren 
indeholder internt en Klasse 1MB (3b)-laser, der nominelt er en 5 
milliwatt galliumarsenid laser, som arbejder pa bolgelaengdeomradet 
770-795 nanometer. Lasersystemet og printeren er udformet 
saledes, at mennesker aldrig udsaettes for en laserstraling over 
Klasse l-niveau ved normal drift, brugervedligeholdelse eller 
obligatoriske servicebetingelser. 



Huomautus laserlaitteesta 

Tama kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 
21 CFR Subchapter J -maarityksen mukainen ja muualla luokan I 
laserlaitteiden IEC 60825 -maarityksen mukainen. 

Luokan I laserlaitteiden ei katsota olevan vaarallisia kayttajalle. 
Kirjoittimessa on sisainen luokan 1Mb (3b) 5 milliwatin 
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometria. 
Laserjarjestelma ja kirjoitin on suunniteltu siten, etta kayttaja ei 
altistu luokan I maarityksia voimakkaammalle sateilylle kirjoittimen 
normaalin toiminnan, kayttajan tekemien huoltotoimien tai muiden 
huoltotoimien yhteydessa. 



VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina 
nakymattomalle lasersateilylle. Ala katso sateeseen. 

VARNING! Osynlig laserstralning nar denna del ar oppnad och 
sparren ar urkopplad. Betrakta ej stralen. 



Laser-notis 

Denna skrivare ar i USA certifierad att motsvara kraven i DHHS 21 
CFR, underparagraf J for laserprodukter av Klass I (1). I andra 
lander uppfyller skrivaren kraven for laserprodukter av Klass I enligt 
kraven i IEC 60825. 

xiv Service Manual 



4069-XXX 

Laserprodukter i Klass I anses ej halsovadliga. Skrivaren har en 
inbyggd laser av Klass 1Mb (3b) som bestar av en laserenhet av 
gallium-arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770- 
795 nanometer. Lasersystemet och skrivaren ar utformade sa att det 
aldrig finns risk for att nagon person utsatts for laserstralning over 
Klass l-niva vid normal anvandning, underhall som utfors av 
anvandaren eller annan foreskriven serviceatgard. 



Laser-melding 

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, 
underkapittel J, for klasse I (1) laserprodukter, og er i andre land 
godkjent som et Klasse l-laserprodukt i samsvar med kravene i I EC 
60825. 

Klasse l-laserprodukter er ikke a betrakte som farlige. Skriveren 
inneholder internt en klasse 1Mb (3b)-laser, som bestar av en 
gallium-arsenlaserenhet som avgir straling i bolgelengdeomradet 
770-795 nanometer. Lasersystemet og skriveren er utformet slik at 
personer aldri utsettes for laserstraling ut over klasse l-niva under 
vanlig bruk, vedlikehold som utfores av brukeren, eller foreskrevne 
serviceoperasjoner. 



Avis sobre el Laser 

Segons ha estat certificat als Estats Units, aquesta impressora 
compleix els requisits de DHHS 21 CFR, apartat J, pels productes 
laser de classe I (1 ), i segons ha estat certificat en altres llocs, es un 
producte laser de classe I que compleix els requisits d'lEC 60825. 

Els productes laser de classe I no es consideren perillosos. Aquesta 
impressora conte un laser de classe 1Mb (3b) d'arseniur de gal.li, 
nominalment de 5 mil.liwats, i funciona a la regio de longitud d'ona 
de 770-795 nanometres. El sistema laser i la impressora han sigut 
concebuts de manera que mai hi hagi exposicio a la radiacio laser 
per sobre d'un nivell de classe I durant una operacio normal, durant 
les tasques de manteniment d'usuari ni durant els serveis que 
satisfacin les condicions prescrites. 



Notices and Safety Information xv 



4069-XXX 



Japanese Laser Notice 



CO-7°'J >*-«, *HT?«DHH S 21 CFRtyfty^-J 

©??xi (l) o**^ffifcLfcu-if-S! D a D-e*,5ci^iiEiP?$ 

tlT^S-To */:*ffljy^T« I E C 8 2 5 ©**£«*: Lfci' 9 
X I ©U-lf-MST'&^Ci^MStlTl^TJ-o 

7 , iJ>i'-U)'7XIb (3b) ©U--tf-«-|*I^LTU*-r„ C© 

u-if-fa, &s*<7 7 o ~ 7 9 5^-y y -^-otSHT, as 

5 J ') 7 -y h©# 'J -> A ilt ft ft* Sfc M ir& U-V-T'-fo C©b~-f 



Chinese Laser Notice 




1 . ;LUt 


• 






*?TEPtfl»MiIiAiiE^^ DHHS 21 CFR 
Subchapter I ##§£ I (1) % * j* i& W # 
7£, ffi&g'ffeWlEIISikffi^ IEC 825 




ft* ep#i ft SP -££#!£ nib (3b) #jM, 



m'M, K^-fcfErK 770-795 nm ZH 



K&mxftmi 



xvi Service Manual 



4069-XXX 



Korean Laser Notice 

esUNfe 1§e SJIOjX-i *m^0\\ cm DHHS 21 
CFR Subchapter 3°| fl^S ^SJ-JJ &£§ 
nR0||A-| °]§£m°tt|, n£|2| M-al-oilAHE. i EC 825 

1€S al|o|7H 7H|gfts oj-^j^ 50^ ^h^Ej L |c(., 
£ H^!N^ 5 SaifiFM a# ohsA||Lho|H 
al|o|7:i^Ai 770-795 4±rin|El2| n|-g-cHo||Ai 
t^Sfe Class III (3b) B||o|AiS L||Jfo|| 5>n 

2AhM4. £ B||0|7H A|^l^ = =!E|£ §& x^e 

&7|2| Class I 4^£| a||o|Ai «j#o|| AplJ-o| gcH 



Safety Information 

• This product is designed, tested and approved to meet strict 
global safety standards with the use of specific Lexmark 
components. The safety features of some parts may not always 
be obvious. Lexmark is not responsible for the use of other 
replacement parts. 

• The maintenance information for this product has been 
prepared for use by a professional service person and is not 
intended to be used by others. 

• There may be an increased risk of electric shock and personal 
injury during disassembly and servicing of this product. 
Professional service personnel should understand this and take 
necessary precautions. 



Consignes de Securite 

• Ce produit a ete concu, teste et approuve pour respecter les 
normes strides de securite globale lors de I'utilisation de 
composants Lexmark specifiques. Les caracteristiques de 

Notices and Safety Information xvii 



4069-XXX 

securite de certains elements ne sont pas toujours evidentes. 
Lexmark ne peut etre tenu responsable de I'utilisation d'autres 
pieces de rechange. 

• Les consignes d'entretien et de reparation de ce produit 
s'adressent uniquement a un personnel de maintenance 
qualifie. 

• Le demontage et I'entretien de ce produit pouvant presenter 
certains risques electriques, le personnel d'entretien qualifie 
devra prendre toutes les precautions necessaires. 

Norme di sicurezza 

• II prodotto e stato progettato, testato e approvato in conformita a 
severi standard di sicurezza e per I'utilizzo con componenti 
Lexmark specifici. Le caratteristiche di sicurezza di alcune parti 
non sempre sono di immediata comprensione. Lexmark non e 
responsabile per I'utilizzo di parti di ricambio di altri produttori. 

• Le informazioni riguardanti la manutenzione di questo prodotto 
sono indirizzate soltanto al personale di assistenza autorizzato. 

• Durante lo smontaggio e la manutenzione di questo prodotto, il 
rischio di subire scosse elettriche e danni alia persona e piu 
elevato. II personale di assistenza autorizzato, deve, quindi, 
adottare le precauzioni necessarie. 

Sicherheitshinweise 

• Dieses Produkt und die zugehorigen Komponenten wurden 
entworfen und getestet, urn beim Einsatz die weltweit gultigen 
Sicherheitsanforderungen zu erfullen. Die sicherheitsrelevanten 
Funktionen der Bauteile und Optionen sind nicht immer 
offensichtlich. Sofern Teile eingesetzt werden, die nicht von 
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder 
Haftung fur dieses Produkt ubernommen. 

• Die Wartungsinformationen fur dieses Produkt sind 
ausschlieBlich fur die Verwendung durch einen 
Wartungsfachmann bestimmt. 

• Wahrend des Auseinandernehmens und der Wartung des 
Gerats besteht ein zusatzliches Risiko eines elektrischen 
Schlags und korperlicher Verletzung. Das zustandige 



xviii Service Manual 



4069-XXX 



Fachpersonal sollte entsprechende VorsichtsmaBnahmen 
treffen. 



Pautas de Seguridad 

• Este producto se ha disenado, verificado y aprobado para 
cumplir los mas estrictos estandares de seguridad global 
usando los componentes especfficos de Lexmark. Puede que 
las caracterfsticas de seguridad de algunas piezas no sean 
siempre evidentes. Lexmark no se hace responsable del uso de 
otras piezas de recambio. 

• La informacion sobre el mantenimiento de este producto esta 
dirigida exclusivamente al personal cualificado de 
mantenimiento. 

• Existe mayor riesgo de descarga electrica y de dahos 
personales durante el desmontaje y la reparacion de la 
maquina. El personal cualificado debe ser consciente de este 
peligro y tomar las precauciones necesarias. 



Informacoes de Seguranga 



• Este produto foi concebido, testado e aprovado para satisfazer 
os padroes globais de seguranga na utilizagao de componentes 
especfficos da Lexmark. As fungoes de seguranga de alguns 
dos componentes podem nao ser sempre obvias. A Lexmark 
nao e responsavel pela utilizagao de outros componentes de 
substituigao. 

• As informagoes de seguranga relativas a este produto 
destinam-se a profissionais destes servigos e nao devem ser 
utilizadas por outras pessoas. 

• Risco de choques electricos e ferimentos graves durante a 
desmontagem e manutengao deste produto. Os profissionais 
destes servigos devem estar avisados deste facto e tomar os 
cuidados necessarios. 



Notices and Safety Information xix 



4069-XXX 



Informacio de Seguretat 

• Aquest producte esta dissenyat, comprovat i aprovat per tal 
d'acomplir les estrictes normes de seguretat globals amb la 
utililitzacio de components especffics de Lexmark. Les 
caracterfstiques de seguretat d'algunes peces pot ser que no 
sempre siguin obvies. Lexmark no es responsabilitza de I'us 
d'altres peces de recanvi. 

• La informacio pel manteniment d'aquest producte esta 
orientada exclusivament a professionals i no esta destinada a 
ningu que no ho sigui. 

• El rise de xoc electric i de danys personals pot augmentar 
durant el proces de desmuntatge i de servei d'aquest producte. 
El personal professional ha d'estar-ne assabentat i prendre les 
mesures convenients. 



xx Service Manual 



4069-XXX 



Chinese Safety Information 

• *^p p pffiffl#WW Lexmark t£#, ^M^teftW^l* 
^K^terWlE^^^Wffiffi, Lexmark «{*£». 



Korean Safety Information 

• & *)|-g§ ^S Lexmark ^£ S4:°| a^o|| °[oi gz|t* 
AMI °j-S S£0|| g££^ -W7II, E||^M£|Sioa1 

^i^steM^. sjy y#^i erS^s s-# as-si*i 

&hM4. Lexmark^ c+# h*|| ^#s| Ahgo|| q^ 

• s. ^[gOi| 3t£j. ^X| fi^ ^gAH^ *t£ Aib|^ 
7|^A^o^ *IMS\ ^0|H^ b| *j-£7fe Al-Sg- ^ 

• £- *U## sHx-iltrT^ §u|si- s ° *l7|*j°i #^s 
!>7ii4 #*j# oj# ^lio| TiSMcK *jg ahh|^ 

7|mA|-^ 0| A(-g# ^^lohni |fig OJI ^h 5*|f 



Ozone Information 

This product does not produce measurable amounts of ozone gas. 



Notices and Safety Information xxi 



4069-XXX 

Preface 



This manual is divided into the following chapters: 

• "General Information" contains a general description of the 
printer, options, and the maintenance approach used to repair it. 
General environmental and safety instructions as well as 
special tools and test equipment are listed in this chapter. 

• "Diagnostic Information" contains a service error code table, 
user status message table, user error message table, symptom 
table, and service checks used to isolate failing field replaceable 
units (FRUs). 

• "Diagnostic Aids" contains tests and checks used to locate or 
repeat symptoms of printer problems. Printer operation 
information is provided to enhance the tests and checks. 

• "Repair Information" provides instructions for making printer 
adjustments and removing and installing FRUs. 

• "Connector Locations" uses illustrations to identify the major 
components and test points on the printer. 

• "Preventive Maintenance" contains safety inspection guidelines, 
lubrication specifications, and maintenance information to 
prevent problems and maintain performance. 

• "Parts Catalog" contains illustrations and part numbers for 
individual FRUs. 



xxii Service Manual 



4069-XXX 



1. General Information 



The Optra™ T laser printers are letter quality page printers designed 
to attach to IBM-compatible PC's and to most computer networks. 

The Optra T laser printer is available in the following models. 



Model Name 


Type 


Optra T 610 


4069-010 


Optra T 61 On 


4069-01 n 


Optra T 61 2 


4069-212 


Optra T 61 2n 


4069-21 n 


Optra T612v 


4069-31 v 


Optra T612vn 


4069-31 e 


Optra T 614 


4069-414 


Optra T 614 


4069-41 b 


Optra T 61 4n 


4069-41 e 


Optra T 61 4nl 


4069-411 


Optra T 61 4n 


4069-41 n 


Optra T 61 6 


4069-616 


Optra T 61 6n 


4069-61 n 



General Information 1-1 



4069-XXX 



Look at the printer serial label to identify the printer you are working 
on. There are two service levels of Optra T printers. Some printers 
are at a service level B as indicated by the B on the label. 




P/N: XXXXXXXX 
CNFG :XXXXXX 

Type : 4069-XXX 

S/N: XX-XXXXX 



P/N: XXXXXXXX 
CNFG :XXXXXX 

Type : 4069-XXX 

S/N: XX-XXXXX 



B 



1-2 Service Manual 



4069-XXX 



Options 

The following options are available. Some options are not available 
in every country. Contact your point of purchase for options available 
in your country. 

Memory options of 4MB, 8MB, 1 6MB, 32MB, 64MB and 1 28MB 
SDRAM DIMM 

Flash memory options of 2MB, 4MB, 8MB and 1 6MB DIMM 
Integrated network options 

Token-Ring 

Ethernet 

Tri-Port Adapter 

I R Adapter 

IPDSSIMM 

Prescribe SIMM 

TIFF SIMM 

Barcode SIMM 

Parallel Interface Card 

SCS 

USB/Parallel Port 

Marknet Print Servers 
250 and 500-sheet paper trays of A5, letter, and legal size. 
250 Sheet Special Media Tray Assembly 
500 Sheet Special Media Tray 
2000 Sheet High Capacity Feeder 
Envelope feeder 
Duplex option - 250 Sheet 
Duplex option - 500 Sheet 
Hard Disk -2.1 GB 
Forms Hard Disk -2.1 GB 
Vertical Kiosk Presenter 
Horizontal Kiosk Presenter 
Output Expander 
5-Bin Mailbox 
High Capacity Output Stacker 



General Information 1-3 



4069-XXX 



Maintenance Approach 

The diagnostic information in this manual leads you to the correct 
field replaceable unit (FRU) or part. Use the service error codes, 
user status messages, user error messages, service checks, and 
diagnostic aids to determine the printer problem and repair the 
failure. After you complete the repair, perform tests as needed to 
verify the repair. 



Tools Required For Service 

Flat-blade screwdriver 

#1 Phillips screwdriver 

#2 Phillips screwdriver 

T10 Torx Screwdriver 

7.0 mm nut driver 

5.5 mm wrench 

Needlenose pliers 

Diagonal pliers 

Spring hook 

Feeler gauges 

Analog or digital multimeter 

Parallel wrap plug 1319128 

Serial wrap plug 1329048 

Twinax/serial debug cable 1381963 

Coax/serial debug cable 1381964 



1-4 Service Manual 



4069-XXX 



Acronyms 




csu 


Customer Setup 


DIMM 


Dual In-Line Memory Module 


DRAM 


Dynamic Random Access Memory 


EDO 


Enhanced Data Out 


EP 


Electrophotographic Process 


EPROM 


Erasable, Programmable Read-Only 




Memory 


ESD 


Electrostatic Discharge 


FRU 


Field Replaceable Unit 


GB 


Gigabyte 


HVPS 


High Voltage Power Supply 


LASER 


Light Amplification by Stimulated Emission 




of Radiation 


LCD 


Liquid Crystal Display 


LED 


Light-Emitting Diode 


LVPS 


Low Voltage Power Supply 


MROM 


Masked Read Only Memory 


NVRAM 


Nonvolatile Random Access Memory 


OEM 


Original Equipment Manufacturer 


PC 


Photoconductor 


POR 


Power-On Reset 


POST 


Power-On Self Test 


RIP 


Raster Imaging Processor 


ROM 


Read Only Memory 


SIMM 


Single In-Line Memory Module 


SDRAM 


Synchronous Dual Random Access 




Memory 


SRAM 


Static Random Access Memory 


UPR 


Used Parts Return 


Vac 


Volts alternating current 


Vdc 


Volts direct current 



General Information 1-5 



4069-XXX 



1-6 Service Manual 



4069-XXX 



2. Diagnostic Information 



Start 



CAUTION: Remove the power cord from the printer or wall outlet 
before you connect or disconnect any cable or electronic board or 
assembly for personal safety and to prevent damage to the printer. 
Use the handholds on the side of the printer. Make sure your fingers 
are not under the printer when you lift or set the printer down. 

Use the service error code, user status message, user error 
message, symptom table, service checks, and diagnostic aids in this 
chapter to determine the corrective action necessary to repair a 
malfunctioning printer. 

Service error codes are indicated by a three-digit error code. If a 
service error code is displayed, go to the "Service Error Codes" on 
page 2-2. 

User status messages provide the user with information on the 
current status of the printer. Ready is displayed on the first line of the 
display unless Power Saver is invoked, and then Power Saver is 
displayed. If a user status message is displayed, go to the "User 
Status Messages" on page 2-12. 

User error messages are indicated by a two or three-digit error code 
that provides the user with information that explains a problem with a 
print cartridge, paper jam, option, port, and so on. If a user error 
message is displayed, go to the "User Error Messages" on page 2-16. 

If your machine completes the "Power-On Self Test (POST)" on 
page 2-24 without an error, and you have a symptom, go to the 
"Symptom Tables" on page 2-25. Locate your symptom and take the 
appropriate action. 

If a service error code appears while you are working on the 
machine, go to the "Service Error Codes" on page 2-2 and take the 
indicated action for that error. 



Diagnostic Information 2-1 



4069-XXX 

Service Error Codes 

Service Error Codes are generally non-recoverable except in an 
intermittent condition when you can POR the printer to temporarily 
recover from the error condition. 



Error Code 


Action 


900 RIP Software 


Contact the next support level or call Lexmark. 


901 Engine Flash 


Indicates that the flash which the engine board code is 
programmed into is bad. Replace the engine board. 


902 General 
Engine Software 


These errors indicate an unrecoverable engine software 
error. Replace the engine board. 

Check for correct location of the jumpers on the 
interconnect board for the model/type printer you are 
servicing. Incorrect jumper settings can cause a 902 
service error. If jumpers are set correctly, replace the 
engine board. 


903 Paperport 
Link Driver Error 


904 Interface 
Violation by the 
controller 
software 


905 Interface 
Violation by 
Paperport Device 


906 Controller- 
Engine Link 
Driver Error 


910 DC Pick 
Motor DC Pick 
Motor Stall 


Error Codes 91 0,91 1 ,91 2,91 3 and 91 4 are indications 
that a Tray 1 paper feed problem has been detected. Go 
to the "Input Tray(s) Option Service Check" on 
page 2-53. 


911 DC Pick 
Motor Excessive 
PWM 


912 DC pick 
motor below 
speed 


913 DC pick 
motor over speed 



2-2 Service Manual 



4069-XXX 



Error Code 


Action 


914 DC pick 
motor: No 
encoder feedback 


Check the integrated paper tray (tray 1) for correct paper 
loading. Reload the paper and POR the printer. If the 
error continues, go to the "Input Tray(s) Option Service 
Check" on page 2-53. 


91 7 Transfer Roll 


Indicates a problem in the transfer roll area. Go to the 
"Transfer Roll Service Check" on page 2-108. 
Note: This error also displays if an incorrect level HVPS 
assembly is installed in a printer that has the erase lamp 
assembly installed. Check to make sure the correct 
HVPS assembly is installed. 


920 Fuser Error 


Indicates that the fuser is below temperature when 
printing. Go to the "Fuser Service Check" on page 2-47. 
For models 31 v and 31 e go to "Belt Fuser" on page 2-50. 


921 Fuser Error 


Indicates that the fuser is below standby temperature 
when the printer is idle. Go to the "Fuser Service Check" 
on page 2-47. 


922 Fuser Error 


Fuser failed to reach standby temperature. Go to the 
"Fuser Service Check" on page 2-47. For models 31 v 
and 31 e go to "Belt Fuser" on page 2-50. 


923 Fuser Error 


Fuser is too hot during printing or when printer is idle. Go 
to the "Fuser Service Check" on page 2-47. For models 
31 v and 31 e go to "Belt Fuser" on page 2-50. 


924 Fuser Error 


An open circuit has been detected in the Fuser 
Thermistor Circuit. Go to the "Fuser Service Check" on 
page 2-47. For models 31 v and 31 e go to "Belt Fuser" on 
page 2-50. 


925 Fuser Error 
010/212/414/616/ 
01n/21n/41b/41l/ 
41n/61n 


Wrong fuser lamp installed. Check the fuser lamp for the 
correct type of lamp that should be installed. 


927 Fan Stalled 


Indicates a printer fan stalled. Go to the "Fan Service 
Check" on page 2-46. 



Diagnostic Information 2-3 



4069-XXX 



Error Code 


Action 


928 Erase Lamps 


Models 01 0/21 2/414/61 6/31 v/01 n/21 n/31 e/41 n/61 n 
Indicates that the engine has detected that either the 
erase lamp assembly is missing or disconnected. Go to 
the "Erase Lamp Service Check (01 0/21 2/41 4/61 6/31 v/ 
01 n/21 n/31 e/41 n/61 n)" on page 2-45. 

Models 41 b/41 e/41 1 and models 01 0/21 2/41 4/61 6/31 v/ 
01 n/21 n/31 e/41 n/61 n at service level B do not have 
erase lamps installed. Go to "Printer Serial Label" on 
page 7-2 to identify the printer service level. Check to 
make sure the correct HVPS is installed if this error 
displays on these models. 


929 Toner Sensor 


The toner sensor is not operating properly, the developer 
drive assembly is not operating properly or the print 
cartridge is defective. Go to the "Toner Sensor Service 
Check" on page 2-1 07. 


930 Printhead 
Error 


The wrong printhead is installed. Replace with the 
correct printhead. 


931-935 
Printhead Error 


These errors represent a problem with the printhead. Go 
to the "Printhead Service Check" on page 2-92. 


932 - Printhead: 
Lost Hsync 


933 -Mirror Motor 
Locks/Lost Hsync 


934 -Mirror Motor 
Lost Lock 


935 -Mirror Motor 
unable to reach 
operating speed. 


936-937 
Transport Motor 


Indicates a problem with the main drive motor. Go to the 
"Main Drive Service Check" on page 2-69. 


936 - Main Drive 
Motor initial lock 
failure 


937 - Main Drive 
Motor lost lock 



2-4 Service Manual 



4069-XXX 



Error Code 


Action 


939 Controller - 
Engine 

Communications 
Error 


The controller board and the engine board cannot 
communicate with one another. The controller board, 
engine board or interconnect board is defective. Check 
each board for correct installation and secure ground. If 
no problem is found, replace the FRUs in the following 
order: 

controller board 

engine board 

interconnect board 

Note: The controller software also can cause a 939 error 
code. Contact your next level for software support. 


941 Controller 
Code CRC 


A 941 error can be created by a defective code overlay 
SIMM, a code upgrade, a defective IPDS or a prescribe 
SIMM. These should be checked before replacing the 
controller board. 


941 Controller 
Font CRC 


Replace the controller board. 


943 Controller 
Font Version 


Indicates that the controller code and FONT ROM are 
incompatible. 


944 Controller 
Board Failure 


Replace the controller board. 


945 Controller 
Board Failure - 
ASIC Failure 


Replace the controller board. 


946 Controller 
Board Failure - 
SRAM Failure 


Replace the controller board. 


947 Engine 
Board 


Replace the engine board. 


953 NVRAM 
Failure 


Indicates the NVRAM chip on the engine board has 
failed. Replace the engine board. 


954 NVRAM 
Failure 


Indicates the NVRAM experienced a CRC failure. 
Replace the engine board. 



Diagnostic Information 2-5 



4069-XXX 



Error Code 


Action 


956 Configuration 
ID 


Indicates a problem with the Configuration ID. This error 
occurs because the engine received a configuration ID 
from the controller software which is not valid for the 
level of engine code existing in the printer. Setting the 
configuration ID correctly should fix this error. The ID can 
be set via the NPA data stream or operator panel. 

Note: This error is not generated at POR to allow the 
servicer a method of resetting the configuration ID. 
However, setting the configuration ID is the only 
operation that the servicer can perform. See "Setting 
Configuration ID" on page 3-21. 


960 RAM 
Memory Error 


Indicates a DRAM Memory Error on the controller board. 
Replace the controller board. 


961 RAM in Slot 
1 is Bad. 


Replace the DIMM in Slot 1 . If this does not fix the 
problem, replace the controller board. 


962 RAM in Slot 
2 is Bad. 


Replace the DIMM in Slot 2. If this does not fix the 
problem, replace the controller board. 


963 RAM in slot 3 
is Bad. 


Replace the DIMM in slot 3. If this does not fix the 
problem, replace the controller board. 


964 Emulation 
Error 


Indicates a failure within the Download Emulation which 
is programmed into the code overlay SIMM. The specific 
error is as follows: 

964 - Download Emulation CRC Failure. Checksum 
Failure. 

965 - Download Emulation Outdated, The Download 
Emulation and the controller code are incompatible. Go 
to "Disabling Download Emulations" on page 3-3. 


965 Emulation 
Error 


975 - 979 
Network Card X 


The following errors indicate a failure with the network 
card in the specified slot. X=any card installed in slots 
1 ,2 or 3. 975 - Unrecognizable Network Card x. Replace 
Network Card x. 

976 - Unrecoverable software error in Network Card x. 

977 - Controller software detects that a Network Card is 
installed in slot x but cannot establish communications 
with it. 

978 - Bad checksum while programming Network Card 
x. Replace Network Card x. 

979 - Flash parts failed while programming Network 
Card x. 

If the printer is a network model, replace the controller 
board. 



2-6 Service Manual 



4069-XXX 



Error Code 


Action 


980 <device> 
Comm 


The engine is experiencing unreliable communications 
to the specified device. 


981 <device> 


The engine protocol violation detected by the specified 
device. 


982 <device> 
Comm 


Communications error detected by the specified device. 


983 <device> 


Invalid command received by the specified device. 


984 <device> 


Invalid command parameter received by the specified 
device. 

Note: Service Errors 980 thru 984 <device> can be one 
of the following: engine board, duplex, tray x (1 ,2,3,4 or 
5), envelope feeder or output bin x (1 ,2 or 3). 


990 <device> 


Indicates an equipment check condition has occurred in 
the specified device, but the device is unable to identify 
the exact component failure. 

Note: <device> can be one of the following: duplex, tray 
x (1 ,2,3,4 or 5), envelope feeder or output bin x(1 ,2 or 3). 


991 <device> 
Card 


The specified device has detected an equipment check 
in its system card. 

Note: <device> can be one of the following: duplex, tray 
x(1 ,2,3,4 or 5), envelope feeder or output bin x (1 ,2 or 3). 



Sub Error Codes For 9XX and 2XX Error Codes 

The sub error codes are helpful troubleshooting a paper path 
problem, especially paper jams in the base printer, envelope feeder 
and duplex unit. 

When a 9XX or 2XX error displays: 

Press and hold return and press select to enter for sub error codes. 



Diagnostic Information 2-7 



4069-XXX 

The following is an example of how the printer displays a duplex unit 
sub error code. 





Bytel 


Byte 2 


Byte 3 


Byte 4 


DU 


XX 


XX 


XX 


XX 


DU 


XX 


XX 


XX 


XX 




Byte 5 


Byte 6 


Byte 7 


Byte 8 



Base Printer Sub Error Codes 

Each status byte has a different level of troubleshooting value for 
each area of the printer. The following table displays status bytes 1 , 
2 and 3. This set of status bytes is designed to help isolate paper 
jams and paper feed problems in the base printer. 



Status 
Bytes 1 , 2,3 


Explanation 


84 xx 00 


The input sensor is still covered by the first sheet of paper 
through the printer and the second sheet is ready to arrive at 
the sensor. 


84 xx 01 


Video information has not started on the page at the input 
sensor within two inches after activating the input sensor flag. 


84 xx 02 


The media takes too long to complete a pass through the 
input sensor. 


84 xx 04 


This can occur when a sheet of paper is in the machine 
during POST and the input sensor flag has tripped the input 
sensor. 


84 xx 05 


This error is generated whenever media is seen at the input 
sensor before the sensor flag activates the input sensor. 


84 xx 06 


A paper jam is detected by the tray you are trying to feed 
from. 


84 xx 07 


A paper jam is detected by a smart option and an error 
message displays. 


84 xx 08 


Paper Tray 5 pass thru sensor is not activated by a sheet of 
paper. 



2-8 Service Manual 



4069-XXX 



Status 
Bytes 1,2,3 


Explanation 


84 xx 09 


Paper Tray 4 pass thru sensor is not activated by a sheet of 
paper. 


84 xx 0A 


Paper Tray 3 pass thru sensor is not activated by a sheet of 
paper. 


84 xx OB 


Paper Tray 2 pass thru sensor is not activated by a sheet of 
paper. 


84 xx OC 


Paper Tray 5 pass thru sensor is not activated and never 
deactivated. A sheet of paper may still be over the sensor or 
the flag is still activated. 


84 xx OD 


Paper Tray 4 pass thru sensor is not activated and never 
deactivated. A sheet of paper may still be over the sensor or 
the flag is still activated. 


84 xx OE 


Paper Tray 3 pass thru sensor is not activated and never 
deactivated. A sheet of paper may still be over the sensor or 
the flag is still activated. 


84 xx OF 


Paper Tray 2 pass thru sensor is not activated and never 
deactivated. A sheet of paper may still be over the sensor. 


84 xx 1 


The main motor is stalled or the incorrect main motor is 
installed in the printer. 


84 xx 1 1 


The paper activated the input sensor too soon. 


84 xx 13 


The paper activated the input sensor too soon. 


84 xx 1 D 


The envelope feeder pass thru sensor is activated and never 
deactivated. 


84 xx 1 E 


The envelope feeder pass thru sensor is not activated. 


84 xx 1 F 


The paper fed too early from Tray 1 . 


84 xx 21 


The smart option did not pick the paper. 


84 xx 22 


The smart option did not pick the paper. 


8E xx 02 


The input sensor is not activated even though the paper is 
picked from the source. 



Diagnostic Information 2-9 



4069-XXX 



Status 
Bytes 1 , 2,3 


Explanation 


8E xx OB 


The autocompensator DC motor stalls when attempting to 
pick a sheet of paper. 


8E xx 1 1 


The autocompensator DC motor takes too long to ramp up. 



Envelope Feeder Sub Error Codes 

Status byte 1 contains the most valuable information to help isolate a 
feed problem with the envelope feeder and is the only byte contained 
in the following table. 



Status 
Bytel 


Explanation 


00 


There was no envelope feeder error reported. 


10 


Printer failed POST - Homing of Envelope feeder 


11 


Printer failed POST - Halted Envelope Feeder 


21 


The envelope feeder failed to feed, envelope jam. 


30 


The D.C. motor failed to reach operating speed. 


32 


The motor stalled. 


36 


The motor failed to stop. 



Duplex Unit Sub Error Codes 

Status byte 4 contains the most valuable information to help isolate a 
failing part or assembly in the duplex option and is the only byte 
contained in the following table. 



Status 
Byte 4 


Explanation 


00 


No duplex error. No problem was reported to the engine by the 
duplex system card. 


01 


The leading edge of the sheet of paper never arrived at the input 
sensor. 



2-10 Service Manual 



4069-XXX 



Status 
Byte 4 


Explanation 


02 


The duplex option system board never received media notification 
from the printer. 


03 


The trailing edge of the sheet of paper never cleared the input 
sensor. 


04 


The leading edge of the sheet of paper never arrived at the exit 

sensor. 

Note: This error is the most common due to the long length of the 

paper path between the input sensor and the exit sensor. 


05 


The duplex logic thinks a sheet of paper is feeding to the duplex 
unit due to a sensor malfunction in the paper path when in fact the 
printer has not sent a command to send a sheet of paper to the 
duplex unit. 


06 


The exit sensor detected a sheet of paper too early. 


07 


The sheet of paper's trailing edge did not clear the exit sensor in 
the desired length of time. 


08 


The feed motor experienced a complete motor stall. 


0E 


The D.C. motor is under speed. The motor never reached the 
correct operating speed. 


13 


There is paper left in the duplex option. Paper was sensed during 
the homing operation during POST. 


15 


There is paper left in the duplex option. Paper was sensed during 
the DC motor diagnostic test during POST. 


18 


The D.C. motor experienced an acceleration error. 


3D 


There is paper left in the duplex option. Paper was sensed during 
IR clear during POST. 



Diagnostic Information 2-11 



4069-XXX 

User Status Messages 



User Status Message 


Status 


Action 


Ready 


The printer is ready to 
receive and process 
data. 


Press Menu> or 
<Menu to take the 
printer out of Ready 
and enter all the 
Menus except the 
TESTS MENU (Busy 
State). 


Ready/Hex 


The printer is ready and 
HEX Trace is active, 
which is known as HEX 
Trace Ready. 


Press Menu> or 
<Menu to take the 
printer out of Ready 
and enter the TESTS 
MENU (Busy State). 
Press Select for the 
values. Press Menu> 
until Reset Printer is 
on the second line of 
the display. Press 
Select to Reset the 
printer. 


Busy 


The printer is busy 
receiving or processing 
data, or printing data. 

Note: The printer 
indicator light blinks 
while the printer is 
processing data. 


Press Stop to take the 
printer out of Busy. 
The Not Ready 
message is displayed. 
No more data is 
processed, but the 
printer processes all 
paper currently in the 
printer paper path. 
Press Go to return to 
Ready. 


Flushing Buffer 


The printer is flushing 
corrupted print data and 
the current print job is 
being discarded. 


No button actions are 
possible while this 
message is displayed. 



2-12 Service Manual 



4069-XXX 



User Status Message 


Status 


Action 


Printing Menu Settings 


The printer is processing 
or printing a list of 
current settings menus 
because Print Menu 
Settings is selected from 
the menu. 


Press Stop to take the 
printer out of Ready. 
The Not Ready 
message is displayed. 
No more data is 
processed, but the 
printer processes all 
paper currently in the 
printer paper path. 
Press Go to return to 
Ready after the page 
prints. Press Menu> 
or <Menu to take the 
printer out of Ready 
and enter the TESTS 
MENU (Busy State). 
Press Select for the 
values. Press Menu> 
until Reset Printer is 
on the second line of 
the display. Press 
Select to reset the 
printer. 


Printing Directory List 


A directory of the flash 
and disk contents is 
processing or printing 
because Print Directory 
is selected from the 
menu. 


Press Stop to take the 
printer out of Ready. 
The Not Ready 
message is displayed. 
No more data is 
processed, but the 
printer processes all 
paper currently in the 
paper path. Press Go 
to return to Ready 
after the page prints. 
Press Menu> or 
<Menu to take the 
printer out of Ready 
and enter the TESTS 
MENU (Busy Stat). 
Press Select for the 
values. Press Menu> 
until Reset Printer is 
on the second line of 
the display. Press 
Select to reset the 
printer. 



Diagnostic Information 2-13 



4069-XXX 



User Status Message 


Status 


Action 


Restoring Factory 
Defaults 


The printer is restoring 
factory defaults. 


No button actions are 
possible while this 
message is displayed. 


Performing Self Tests 


The printer is running 
the normal series of 
start-up tests after it is 
powered On. When the 
tests are complete, the 
printer returns to Ready. 


No button actions are 
possible while this 
message is displayed. 


Not Ready 
(Press Go) 


The printer is in the Not 
Ready state, which 
means it is not ready to 
receive or process data. 
This message displays 
when Menu> or <Menu 
is pressed during a print 
job. 


Press Go to take the 
printer out of the Not 
Ready state. Press 
Menu> or <Menu to 
take the printer out of 
Ready and enter the 
TESTS MENU (Busy 
state). Press Menu> 
until Reset Printer is 
on the second line of 
the display. Press 
Select to reset the 
printer. 


Resetting Printer 


The printer is deleting 
any print jobs in process 
and restoring all settings 
to user defaults. 


No button actions are 
possible while this 
message is displayed. 


Formatting Flash 
(Do Not Power Off) 


The flash memory is 
being formatted. 


No button actions are 
possible while this 
message is displayed. 


Program Flash 
(Do Not Power Off) 


The flash memory is 
being programmed, 
which means fonts or 
macros are being written 
to flash memory. 


Do not perform any 
button actions while 
this message is 
displayed. 


Formatting Disk 


The disk is being 
formatted. 


No button actions are 
possible while this 
message is displayed. 



2-14 Service Manual 



4069-XXX 



User Status Message 


Status 


Action 


Programming Disk 
(Do Not Power Off) 


The disk is being 
programmed, which 
means fonts or macros 
are being written to disk. 


No button actions are 
possible while this 
message is displayed. 

Note: If information is 
written to flash 
memory and to disk at 
the same time, the 
Program Flash 
message is displayed. 


Menus Disabled 


The printer menus have 
been disabled. This 
occurs when Menu> or 
<Menu is pressed while 
the printer is Ready and 
Menu Lockout is active. 
The printer display 
shows this message for 
one second and then 
returns to the Ready 
message. 


No button actions are 
possible while this 
message is displayed. 


Activating Menu 
Changes 


The printer is reset to 
activate a printer setting 
changed in the menus. 


No button actions are 
possible while this 
message is displayed. 



Diagnostic Information 2-15 



4069-XXX 

User Error Messages 



User Error Message 


Explanation 


200 Paper Jam 
Remove Cartridge 


Paper is jammed at the printer Input Sensor. 
Open the printer's upper front door and remove 
the print cartridge to access the paper jam area. 


201 Paper Jam 
Remove Cartridge 


Paper is jammed between the printer's input and 
exit sensors. Open the printer's upper front door 
and remove the print cartridge to access the jam 
area. 


202 Paper Jam 
Open Rear Door 


Paper is jammed at the printer exit sensor. Open 
the printer rear door to access the jam area. 


230 Paper Jam 
Check Duplex 


The paper is most likely jammed in the Duplex 
Unit. Remove the duplex front cover to access the 
jam area. If the paper is jammed in the rear of the 
duplex, then replace the duplex front cover and 
open the duplex rear door. If the paper is not 
jammed in the duplex unit, then it may be jammed 
in the rear of the printer. Open the printer rear 
door to access the jam. 


24X Paper Jam 
Check Tray X 


Paper is jammed around Tray X (X=tray 1 thru 5). 
Try opening Tray X. If the tray is difficult to 
remove, then you may have to remove the tray 
above or below tray X to remove the jammed 
pages. 


250 Paper Jam 
Check MP Feeder 


Paper is jammed in the multipurpose feeder. 


260 Paper Jam 

Check Envelope Feeder 


Paper is jammed in the envelope feeder. 


27X Paper Jam 
Check Output Bin X 


Paper is jammed in output bin X (X=1 thru 3). 
Open the rear door of Output Bin X to access the 
jammed pages. 


Insert Cartridge or Close 
Door 


This message displays when the printer's front 
door is open or the print cartridge is missing. 
If this message cannot be cleared go to "Cover 
Open Switch/Cable Service Check" on page 2-31 . 



2-16 Service Manual 



4069-XXX 



User Error Message 


Explanation 


31 Defective Print 
Cartridge 


Error code 31 is displayed when the top front 
cover is closed and a defective print cartridge is 
detected. It may take the printer 1 0-20 seconds to 
determine if the print cartridge is defective. 
Depending on the setting of the Machine Class ID 
the printer may be allowed to print pages during 
this 1 0-20 second interval. If pages are allowed to 
print, they are not reprinted once a good print 
cartridge is inserted. 

Note: This error indicates the printer was able to 
read the cartridge ID, but the ID did not pass the 
verification test. To pass the verification test, the 
ID read from the print cartridge must match the ID 
from the last "good" print cartridge or the same ID 
must be read from the print cartridge twice. The 
last "good" print cartridge ID is stored in NVRAM. 


32 Unsupported Print 
Cartridge 


Error 32 is displayed when the top cover is closed 
and an unsupported print cartridge is detected. It 
may take the printer 10-20 seconds to determine 
if the print cartridge is supported. Depending on 
the setting of the Machine Class ID the printer 
may be allowed to print pages during this 1 0-20 
second interval. If pages are allowed to print, then 
they are not reprinted once a good print cartridge 
is inserted. If this does not fix the problem, go to 
"Smart Cartridge Service Check" on page 2-106. 


34 Short Paper 


The printer determines the paper length is too 
short to print the formatted data. This occurs 
when the printer does not know the actual paper 
size loaded in the tray. For auto-size sensing 
trays, this error occurs if the paper stop is in the 
incorrect position. Make sure the Paper Size 
setting is correct for the size paper that is being 
used. 


36 Resolution Reduced 


The resolution of the page has been reduced 
from 600 dpi to 300 dpi in order to prevent a 
Memory Full error. This message can only occur if 
the Resolution Reduction setting is turned on. 

Note: 1200 dpi pages are not resolution reduced. 
If a 1 200 dpi job runs out of memory, a Memory 
Full error is displayed. 



Diagnostic Information 2-17 



4069-XXX 



User Error Message 


Explanation 


37 Insufficient Collation 
Memory 


This message is displayed when the printer 
memory used to store pages is too full to collate 
the print job. 


38 Memory Full 


This message is displayed when the printer 
memory used to store pages is full. 


39 Complex Page 


This message is displayed when the page is too 
complex to print. 


51 Defective Flash 


This message is displayed when the printer 
detects a defective flash. This error may occur at 
power on, or during flash format and write 
operations. Press Go to clear the message. The 
flash is marked as bad and normal operation 
continues. Flash operations are not allowed until 
the problem is resolved. 


52 Flash Full 


This message is displayed when there is not 
enough free space in the flash memory to hold 
the resources that have been requested to be 
written to flash. 


53 Unformatted Flash 


This message is displayed when the printer 
detects an unformatted flash at power on. Press 
Go to clear the message. The flash is marked as 
bad and normal operation continues. Flash 
operations are not allowed until the flash is 
formatted. 


54 Standard Serial Error 


This error is displayed when a serial error 
(framing or parity) is detected on the standard 
serial port. This usually indicates the serial port is 
not set up correctly. 


54 Serial Option X Error 


This error is displayed when a serial error 
(framing or parity) is detected on the optional 
serial port. This usually indicates the optional 
serial port is not set up correctly. 


56 Standard Serial 
Disabled 


This error is displayed when data is sent to the 
printer across the standard serial port, but the 
port has been disabled. 



2-18 Service Manual 



4069-XXX 



User Error Message 


Explanation 


56 Parallel Port Disabled 


This error is displayed when data is sent to the 
printer across the parallel port, but the parallel 
port has been disabled. Once this message is 
displayed, reporting of further errors is 
suppressed until the menus are entered, or the 
printer is reset. 


58 Too Many Trays 
Attached 


This error code is displayed when too many input 
trays are attached to the printer. 


58 Too Many Bins 
Attached 


This error code is displayed when too many 
optional output bins are attached to the printer. 


58 Too Many Disks 
Installed 


This error is displayed when too many disks are 
attached to the printer. 


61 Defective Disk 


This error code is displayed when the printer 
detects a defective disk. This error may occur at 
power on or during disk format and write 
operations. The following actions may be taken 
while this message is displayed: Press Go to 
clear the message. The disk is marked defective 
and normal printer operations continue. Disk 
operations are not allowed with a defective disk. 
The Format Disk menu is not shown. 


62 Disk Full 


This error code is displayed when there is not 
enough free space on the disk to hold the 
resources that have been requested to be written 
to the disk. This message displays for both 
resource and PostScript Disk operators when the 
disk is full. 


63 Unformatted Disk 


This error code displays when the printer detects 
an unformatted disk at power on. Press Go to 
clear the message. The disk is marked as bad 
and normal operation continues. Disk operations 
are not allowed until the disk is formatted. 


80 Scheduled 
Maintenance 


The operator panel displays this message at each 
300K page count interval. It is necessary to 
replace the fuser assembly, transfer roller, and 
charge roll at this interval to maintain the print 
quality and reliability of the printer. The parts are 
available as a maintenance kit. For more 
information, go to "Scheduled Maintenance" on 
page 6-2. 



Diagnostic Information 2-19 



4069-XXX 



User Error Message 


Explanation 


81 Engine Code CRC 
Failure 


This error displays when the microcode to be 
programmed in the engine flash code module has 
failed a CRC check. Press Go to clear the 
message. The microcode data is discarded and 
must be re-transmitted from the host computer. 


88 Toner Low 


This message displays when toner low occurs 
and the toner low alarm is activated. Press Go to 
clear this message. 



User Line 2 Messages 

If none of the conditions exist that are listed in the following table, 
line 2 is blank. If any of the messages in the table are displayed the 
following actions can be taken: 

Press Menu> or <Menu to take the printer offline and access the 
Ready Menu group. 

Note: The Menu buttons are not active if Menu Lockout is turned 
on. 

Press Stop to take the printer offline. The Not Ready message is 
displayed. No more data is processed from the host computer. Press 
the Go button to return the printer to the Ready state. 



User Message 


Explanation 


Toner Low 


If the toner cartridge is low, then "Toner Low" 
displays. The Toner Low condition clears 
whenever the upper front door is opened, and 
Toner Low displays again if the condition exists 
after the upper front door is closed. 


Tray X Missing 


If any of the input trays are missing, then "Tray X 
Missing" displays (where X designates which Tray 
(1 through 5) is missing. If multiple trays are 
missing, they are prioritized in this order: Tray 1 , 
2..., then tray 5. Tray X Missing status clears 
whenever Tray X is reinserted. 



2-20 Service Manual 



4069-XXX 



User Message 


Explanation 


Tray X Empty 


If any of the input trays are empty, then "Tray X 
Empty" displays where X designates which tray 
(Tray 1 through 5) is empty. If multiple trays are 
empty, then they are prioritized in this order: Tray 
5, Tray 4, ...Tray 1. 

Note: Tray X Empty status clears whenever Tray 
X is removed. When Tray X is reinserted, it is 
examined and the appropriate status, if any, 
displays. Also note that Empty status is not 
displayed for the Envelope Feeder or 
Multipurpose Feeder. 


Tray X Low 


If any of the input trays are low, then "Tray X Low" 
displays where X designates which tray (1 
through 5) displays. If multiple trays are low, they 
are prioritized in the following order: Tray 
5,4,3,2,1. 

Note: Tray X Low clears whenever Tray X goes 
empty, or Tray X is removed. When Tray X is 
reinserted, it is examined and the appropriate 
status, if any, displays. 

Note: The printer cannot detect when the 
envelope feeder or multipurpose feeder are low. 



User Line 2 Link Messages 

If the printer is locked on a particular link, the link indication displays. 
If the printer is ready to process any link, no messages display. The 
link messages are listed in the following table. 



User Message 


Explanation 


Parallel 


Standard Parallel Port, if available. 


Serial 


Standard Serial Port, if available. 


Serial X 


Serial Port, where X=1 ,2,3, is attached to PCI 
connector X. 


Network X 


Network card X, X=1 ,2,3, is attached to PCI 
connector X. 



Diagnostic Information 2-21 



4069-XXX 



User Message 


Explanation 


LocalTalk X 


LocalTalk Card X,X=1 ,2,3, is attached to PCI 
connector X. 


Infrared 


Standard Infrared port, if available. 


Infrared X 


Infrared Port X, X=1 ,2,3, is attached to PCI 
connector X. 



Check Device Connection Messages 

The messages in the following table display when the printer looses 
communications with one of the following devices. 



User Status Message 


Explanation 


Check Output Bin X 
Connection 


Check Output Bin X (X=1 ,2, or 3). 


Check Env Feeder 
Connection 


Check Envelope Feeder Option Connection. 


Check Tray X 
Connection 


Check Tray X (X=1 ,2,3,4 or 5). 


Check Duplex 
Connection 


Check Duplex Option Connection. 



2-22 Service Manual 



4069-XXX 

The messages in the following table can occur in two ways. The 
specified device could have been removed from the printer, for 
instance to clear a paper jam. Otherwise, the device can still be 
attached to the printer, but is experiencing a communications 
problem, not fully connected, or having a hardware failure. 

• If the device is temporarily removed or not connected properly, 
then reattach it. When the option is recognized, the printer 
automatically clears the error and continues. 

• If the option is experiencing a hardware problem, turn the printer 
off and back on. If the error occurs again, turn the printer off, 
remove the option and call for service. 



User Status Message 


Explanation 


Turn Printer OFF to 
Enable Option 


This message displays when a printer option, 
Input Tray, Output Bin or Envelope Feeder, has 
been attached while the printer is powered On. In 
order to use the option, the printer must first be 
powered off and back on again. Data loss results 
if print jobs are active when the printer is power 
cycled. If a print job is active, then remove the 
option and finish the job. The printer automatically 
clears the message once the option is removed. 
Once the job is complete, turn off the printer and 
attach the option again. 


Insert Duplex Front 
Cover 


This message displays when the duplex front 
access cover is not installed. 


Close Duplex Rear Door 


This message displays when the duplex rear door 
is open. 



Diagnostic Information 2-23 



4069-XXX 

Power-On Self Test (POST) 

When you turn the printer On, it performs a Power-On Self Test. 
Check for correct POST functioning of the base printer by observing 
the following: 

1 . The LED comes on. 

2. The operator panel displays one and a half row of pels, and then 
clears. 

3. Diamonds scroll across the display, and then clear. 

4. The operator panel displays one and a half row of pels, and then 
clears. 

5. The top line of the operator panel displays one square block of 
pels that turn on one at a time until all sixteen blocks display and 
then they all turn off. 

6. "Performing Self Test" appears on the display. 

- The 2000 sheet high capacity option elevator tray moves to 
the uppermost position if installed. 

- The duplex option is checked if installed. 

- The output expander option exit rollers turn if installed. 

7. "Busy" appears on the display. 

8. The fuser lamp turns on. The fuser takes longer to warm up 
from a cold start than a warm start. (All models except the 31 v) 

9. The main fan turns on. 

1 0.The main drive motor turns on. 

1 1 The developer drive assembly drives the developer shaft in the 
toner cartridge. 

12. The exit rollers turn. 

13. The operator panel LED starts blinking. 

14. Models 414 and 616 only - The auxiliary fan turns on and 
continues to run until the printer is powered off. 

1 5. "Ready" appears on the display. 



2-24 Service Manual 



4069-XXX 

Symptom Tables 

Symptom Table - Base Printer 



Symptom 


Action 


Auxiliary Fan (41 4/616) fails to run 
or is noisy. 


Go to the "Auxiliary Fan Service 
Check" on page 2-46. 


Dead Machine 


Go to the "Dead Machine Service 
Check" on page 2-32. 


Operator Panel - One or more 
buttons do not work. 


Go to the "Operator Panel Buttons 
Service Check" on page 2-70. 


Operator Panel - Display is blank. 
Printer sounds 5 beeps. 


Go to the "Operator Panel Service 
Check" on page 2-70. 


Operator Panel - Display is blank. 
Printer does not sound 5 beeps. 


Replace the operator panel 
assembly. 


Operator Panel continuously 
displays all diamonds, sounds 5 
beeps and does not complete 
POST. 


Go to the "Operator Panel Service 
Check" on page 2-70. 


Paperfeed problems - Base 
printer or Integrated 250 Paper 
Tray 


Go to the "Paper Feed Service 
Check" on page 2-89. 


Paper jams at exit of Redrive 
Assembly - No Duplex Option 
installed. 


Go to the "Paper Feed Service 
Check" on page 2-89. 


Paper jams at exit of Redrive 
Assembly - Duplex Option 
installed 


Go to the "Duplex Option Service 
Check" on page 2-35. 


Fuser Solenoid fails to operate. 
(All models except the 31 v) 


Go to the "Fuser Solenoid Service 
Check" on page 2-51. 


Print quality - Black page 


Go to "Print Quality - All Black Page" 
on page 2-94. 


Print quality - Blank page 


Go to "Print Quality - Blank Page" on 
page 2-94. 


Print quality - Light print 


Go to "Print Quality - Light Print" on 
page 2-1 04. 



Diagnostic Information 2-25 



4069-XXX 



Symptom 


Action 


Print quality - Background 


Go to "Print Quality - Background" 
on page 2-98. 


Print quality - Residual image 


Go to "Print Quality - Residual 
Image" on page 2-103. 


Print quality - Skew 


Go to the "Paper Feed Service 
Check" on page 2-89. 


Print quality - Banding 


Go to "Print Quality - Banding" on 
page 2-1 01. 


Print quality - Random marks 


Go to "Print Quality - Random 
Marks" on page 2-96. 


Print quality - Toner on backside 
of printed page 


Go to "Print Quality - Toner on 
backside of printed page" on 
page 2-1 05. 


Print quality - Vertical black bands 
on edge of copy 


Go to "Print Quality - Black bands on 
outer edges of the page" on 
page 2-1 01. 


Unable to clear a 
"32-Unsupported Print Cartridge" 
User Error Message 


Go to "Smart Cartridge Service 
Check" on page 2-106 



Symptom Table - High Capacity Feeder Option (2000 Sheet) 



Symptom 


Action 


The printer does not recognize 
the high capacity feeder option 
installed. 


Go to the "High Capacity Feeder 
Input Tray Service Check" on 
page 2-56. 


Paper feed problem with the high 
capacity feeder option. 


Go to the"High Capacity Feeder 
Input Tray Service Check" on 
page 2-56. 



2-26 Service Manual 



4069-XXX 

Symptom Table: Paper Tray Options 



Symptom 


Action 


Paper feed problem with 250 
Sheet Paper Tray Option. 


Go to the "Input Tray(s) Option 
Service Check" on page 2-53. 


Paper feed problem with 500 
Sheet Paper Tray Option. 


Go to the "Input Tray(s) Option 
Service Check" on page 2-53. 


Media fails to pass thru from the 
lower attached Paper Tray option 
to the next higher mounted option. 


Go to the "Input Tray(s) Option 
Service Check" on page 2-53. 



Symptom Table - Duplex 



Symptom 


Action 


Paper feed problem with Duplex 


Go to the "Duplex Option Service 
Check" on page 2-35. 


Paper jams at Paper Removal 
Tray 


Go to the "Duplex Option Service 
Check" on page 2-35. 


Paper skews in the Duplex Option 


Go to the "Duplex Option Service 
Check" on page 2-35. 


Paper fails to pass from lower 
option thru the Duplex Option. 


Go to the "Duplex Option Service 
Check" on page 2-35. 



Symptom Table - Envelope Feeder Option 



Symptom 


Action 


Envelopes do not feed from the 
envelope feeder. 


Go to the "Envelope Feeder Option 
Service Check" on page 2-38. 


Envelopes do not feed properly 
into base printer. 


Go to the "Envelope Feeder Option 
Service Check" on page 2-38. 



Diagnostic Information 2-27 



4069-XXX 

Symptom Table - Output Expander 



Symptom 


Action 


Printer does not display Output 
Bin Full 


Go to the "Output Bin Sensor 
Standard Tray Service Check" on 
page 2-74. 


Paper does not feed all the way 
into the output tray. 


Go to the "Output Expander Service 
Check" on page 2-75 



Service Checks 

Note: Anytime the engine board is replaced, the Configuration ID 
must be reset in NVRAM on the new engine board. Go to "Setting 
Configuration ID" on page 3-21. 

Review the following information before performing any service 
checks. 

• Paperfeed Problems (especially paper jams): Go to "Viewing the 
Error Log" on page 3-8 and check the printer error log for 
indications of repetitive entries that help to isolate a problem to 
a particular area of the printer or option. 

• Paperfeed Problems with error message: Use the "Sub Error 
Codes For 9XX and 2XX Error Codes" on page 2-7 to help diagnose 
the problem. 

• Print Quality Problems: Go to "Print Quality Test Pages" on 
page 3-24 and print a test page to help diagnose problems 
before changing any settings or working on the printer. 

• Use the resident diagnostics test provided to help isolate a 
problem before taking the machine apart or removing any 
options. 



2-28 Service Manual 



4069-XXX 

Charge Roll Service Check 

Service Tip: Close and evenly spaced repetitive marks 47.1 9 mm 
(1 .86 inch) apart or spots on the page can be caused by a damaged 
or contaminated charge roll. 

Service Tip: Check to make sure the right charge roll arm bushing is 
correctly installed and operates correctly. 

To remove the charge roll: 

1 . Wrap a piece of plain white paper around the charge roll to 
prevent contamination or damage. 

2. Carefully remove the roll by pressing outward and to the right on 
the charge roll link arm and remove the charge roll from the 
right side charge roll bearing. 

3. Remove the charge roll from the left side charge roll bearing 
and remove the roll from the printer. Leave the paper wrapped 
around the charge roll until it is reinstalled. 





FRU 


Action 


1 


Charge Roll Assembly 


Check the charge roll for correct 
installation, toner buildup, marks, 
cuts or other signs of contamination 
or damage. Replace as necessary. 


2 


Left Side Charge Roll Link 


Check the left side charge roll link 
assembly for correct assembly 
operation. Check for damage to the 
arm or bearing assembly. 



Diagnostic Information 2-29 



4069-XXX 





FRU 


Action 


3 


Right Side Charge Roll Link 
Right Charge Roll Bushing 


Check the right side charge roll link 
assembly for correct assembly 
operation. If incorrect, replace the 
charge roll link assembly with the 
charge roll link assembly kit. If 
correct, check the right charge roll 
link assembly bearing for signs of 
wear or contamination. Excessive 
contamination could cause 
intermittent charging of the charge 
roll. If incorrect, replace the link 
assembly. Check for continuity of the 
right link assembly from the bearing 
to the charge roll high voltage 
contact on the right side frame. If 
incorrect, replace the link assembly. 

Make sure the charge roll bushing is 
installed and operating correctly. 

Note: The screw that attaches the 
charge roll lead to the contact must 
be secure. 



2-30 Service Manual 



4069-XXX 

Cover Open Switch/Cable Service Check 





FRU 


Action 


1 


Toner Cartridge 


Check the toner cartridge to make 
sure it is correctly installed and that 
the right and left cartridge tracks are 
not loose or broken. Check to make 
sure the cover open switch activation 
tab on the toner cartridge is not 
broken and that the tab correctly 
activates the cover open switch 
spring. 


2 


Cover Open Switch/Cable 
Assembly 


Check the cover open switch for 
proper mechanical operation. If 
incorrect, repair as necessary. 
Disconnect the cover open switch 
cable from J4 at the engine board 
and measure the voltage at J4-3. It 
measures approximately +5 V dc. If 
the voltage is incorrect, replace the 
engine board. If the voltage is 
correct, check the voltage at J4-1 . If 
the voltage measures greater than 
+1 .0 V dc, replace the engine board. 
If the voltage is correct, check the 
continuity between J4-1 and J4-3 on 
the cable. If no change in continuity 
occurs as the switch is activated, 
replace the cover open switch/cable 
assembly. If the continuity changes 
as the switch is activated, replace 
the engine board. 

Note: It is easier to check the 
voltages on J4 with the controller 
board removed. 



Diagnostic Information 2-31 



4069-XXX 

Dead Machine Service Check 

Note: If a high capacity input tray is installed, remove the option and 
check the base printer for correct operation. If the base printer 
operates correctly, go to "High Capacity Feeder Input Tray Service 
Check" on page 2-56. If the base printer continues to not operate 
correctly, remove any other attached paper handling options. 
Observe all necessary ESD precautions when removing and 
handling the controller board, engine board or any of the installed 
option cards or assemblies. 

Service Tip: When removing the LVPS from the printer observe the 
following: 

1 . The LVPS uses a self docking connector that mates with 
another connector mounted on the left side frame assembly. 
Some force may be required to pull the LVPS loose from the 
connector. 

2. Gently remove the LVPS supply using caution not to damage 
the printed circuit board. Pull the LVPS out far enough to reach 
the fuser lamp cable. 

3. The fuser lamp cable uses a locking type of connector system. 
Unlock the fuser lamp cable connector, disconnect the cable 
and remove the LVPS from the printer. 

Note: If the LVPS is blowing fuses, remove the LVPS from the 
printer. Check the metal LVPS shield for signs of damage that 
causes the shield to touch components on the LVPS board 
assembly. 





FRU 


Action 


1 


Line Voltage 


Check the AC line voltage. If the line 
voltage is incorrect, inform the 
customer. 


2 


AC Line Cord 


Check the line cord for any signs of 
damage. If correct, check the 
continuity of the line cord and 
replace if necessary. 



2-32 Service Manual 



4069-XXX 





FRU 


Action 


3 


+5 V dc at any Option 
Connector 


Check for +5 V dc on any of the 
option connectors. The easiest to 
access is the envelope feeder 
connector located behind the lower 
front door. If +5 V dc is present at 
any of the connectors, go to step 9. If 
+5 V dc is not present, go to step 4. 


4 


+5 V dc at the controller 
board test point 


Check for +5 V dc at the +5 V dc test 
pad located on the controller board. 
If correct, go to step 9. 


5 


+5 V dc at the engine board 
Test Point 


Check for +5 V dc at the +5 V dc test 
point on the engine board. If correct, 
replace the engine board. If 
incorrect, go to step 6. 


6 


LVPS Fuse F1 


Remove the LVPS from the printer 
and check fuse F1 . Replace the fuse 
if the fuse is blown. 


7 


LVPS Fuse F1 - Continues 
to blow after LVPS installed 
in the printer. 


Replace fuse F1 if necessary. Turn 
the LVPS on/off switch Off and 
connect the AC line cord and turn 
the LVPS On. 

CAUTION: Before checking fuse F1 
turn the LVPS Off and disconnect 
the AC line cord. Check fuse F1 . If 
the fuse is blown, replace the LVPS. 


8 


LVPS 


Remove the LVPS from the machine. 
CAUTION: Before making any 
measurements on the LVPS output 
connector, observe all necessary 
safety precautions before applying 
AC power. Measure the voltage on 
LVPS output connector CN3. The 
voltage measures +5 V dc. If 
incorrect, replace the LVPS. 



Diagnostic Information 2-33 



4069-XXX 





FRU 


Action 


9 


Engine Board 


Turn the printer off and disconnect 
all the cables from the engine board. 
Check for +5 V dc at the engine 
board test point. If incorrect, replace 
the FRUs in the following order: 

engine board 

interconnect board 

If correct, turn the printer off and 
reconnect one cable at a time until 
you find the defective assembly. 

Service Tip: A short or low 
resistance load that is attached to 
the engine board can cause the 
LVPS to overcurrent and shut the 
+5 V dc supply down to V dc. 

Service Tip: Check the engine board 
for burn marks or other damage, 
especially R20,R21, R22 and R23 
located next to the upper left engine 
board mounting screw. If this screw 
is overtightened it might deform the 
engine board shield and cause it to 
short out these resistors. 



2-34 Service Manual 



4069-XXX 

Duplex Option Service Check 

The printer does not recognize the Duplex Option is attached. The 
printer does not recognize tray options below the duplex option 
are installed. 





FRU 


Action 


1 


Fuse F1 on Duplex Option 
System Board 


If fuse F1 is blown, replace the fuse. 
If fuse F1 continues to blow, check 
the stepper motor for a short 
between the motor case and pins 
J3-1 through J3-4. If no problem is 
found, check the D.C. servo motor 
pins J1-1 and J1-2 to the motor 
housing for a short. If a short is 
found, replace the motor assembly. If 
no short is found, replace the system 
board. 


2 


Autoconnect Cables/ 
Connectors 


Check the autoconnect cables for 
damage to the cables or the pins in 
the connectors. If damaged, replace 
the cable(s). If no damage is found, 
check to make sure the cables are 
connected to J9, J10, J11 andJ12 
on the duplex system board. If no 
problem is found, replace the duplex 
system board. 



Diagnostic Information 2-35 



4069-XXX 

POST fails, 230 Paper Jam, Check Duplex message displays. 





FRU 


Action 


1 


Duplex D.C. Servo Drive 
Motor 


Check the D.C. servo motor cables 
for signs of cuts or other damage. 
Check the D.C. servo motor sensor 
cable connector for pin damage. If 
no problem is found, replace the 
FRUs in the following order: 

D.C. motor assembly 

duplex option system board 


2 


Input Sensor, Input Sensor 
Flag 


Run the Duplex Sensor Test from the 
diagnostics menu. If the test fails, 
check the input sensor cable at J5 
on the system board for correct 
installation. If no problem is found, 
replace the FRUs in the following 
order: 

input sensor assembly 

duplex option system board 


3 


Paper Exit Sensor and Flag 


Check the duplex exit sensor for 
correct installation and free 
movement of the sensor flag. Check 
to make sure the sensor cable is 
connected to J8 on the system 
board. If no problem is found, 
replace the FRUs in the following 
order: 

exit sensor assembly 

duplex option system board 



2-36 Service Manual 



4069-XXX 

230 Paper Jam - Check Duplex message displays. The page is not 
duplexed and only exits half way out of the redrive. 





FRU 


Action 


1 


Duplex Stepper Motor 


Check the stepper motor cable for 
cuts or pinched wiring. Check the 
routing of the motor leads along the 
left side of the bottom tray. Check for 
correct installation of the motor cable 
connector at J3 on the system 
board. Check for any shorts between 
each pin of the motor cable and the 
motor housing. If shorts are found, 
replace the motor. Check the 
resistance of the stepper motor 
between J3-1 (Stpmtr A-) to J3-2 
(Stpmtr A+). The resistance 
measures approximately 10 ohms. 
The resistance between J3-3 
(Stpmtr B-) to J3-4 (Stpmtr B+) 
measures approximately 10 ohms. If 
the resistance is incorrect, replace 
the stepper motor. Check for shorts 
between windings on pins J3-1 to 
J3-2 and pins J3-3 to J3-4. If a short 
is found, replace the stepper motor 
assembly. If no short is found, 
replace the duplex system board. 



Diagnostic Information 2-37 



4069-XXX 

Envelope Feeder Option Service Check 

Service Tip: Check the envelope feeder paper path for any debris, 
pieces of envelope and so on. If any other options are installed make 
sure they are operating normally. If only the envelope feeder is failing 
to operate correctly, continue with this service check, otherwise go to 
the Interconnect Card Service Check. 

Service Tip: The envelope feeder option receives its +5 V dc 
operating voltage from the +24 V dc bulk at J1-7. If +24 V dc is not 
present at J1 -7, tray 1 is the only tray option that is recognized. 

Note: If a 260 Paper Jam Check Envelope message displays, check 
the "Sub Error Codes For 9XX and 2XX Error Codes" on page 2-7. 

Printer does not recognize the envelope feeder as an attached 
input option. 





FRU 


Action 


1 


Envelope Feeder 


Check to make sure the envelope 
feeder is correctly installed and 
mated to the autoconnect at the front 
of the printer. 


2 


Front Autoconnect on 
Printer 


Check the connector for signs of 
damage to the connector or 
contacts. If you find damage, replace 
the damaged cable/connector 
assembly. Remove the envelope 
feeder option and check the voltages 
at the autoconnect on the front of the 
printer. If incorrect, check the 
interconnect board. If correct, 
reinstall the envelope option and 
continue with step 3. 



2-38 Service Manual 



4069-XXX 





FRU 


Action 


3 


Autoconnect on the 
Envelope Option 


Check the connector for any signs of 
damage to the connector or 
contacts. If you find damage, replace 
the damaged cable/connector 
assembly. Disconnect the 
autoconnect cable at J1 on the 
envelope system board and 
measure the following voltages: 

J 1-3 measures +5 V dc 
J 1-5 measures +5 V dc 
J1-7 measures +24 V dc 

If any of the voltages are incorrect, 
replace the autoconnect 
cable/connector. If the voltages are 
correct, replace the envelope system 
board. 



Diagnostic Information 2-39 



4069-XXX 

Operator panel displays 260 Paper Jam immediately when 
envelope feed is requested - POST incomplete. 





FRU 


Action 


1 


Pass through Sensor 


Check for any debris, pieces of 
envelope and so on over the pass 
thru sensor. Check for correct 
installation of the pass thru sensor 
flag. Make sure the sensor cable is 
attached to the envelope system 
board. Perform an envelope feeder 
sensor test to check both the sensor 
and sensor flag. 

Note: It may be necessary to use a 
small tool to actuate the sensor flag 
because it is located under the front 
cover. Be careful not to damage the 
flag. 

If the test fails, check the flag for any 
signs of damage or binds. If 
incorrect, replace the flag. If the flag 
is operating correctly, check the 
voltage at J3-3. The voltage 
measures approximately +5 V dc. If 
incorrect, replace the envelope 
system board. If correct, check the 
voltage at J3-2. The voltage changes 
from to +5 V dc when the flag is 
moved in and out of the sensor. If 
incorrect, replace the sensor 
assembly. If this does not fix the 
problem, replace the envelope 
system board. 



2-40 Service Manual 



4069-XXX 

Operator panel displays 260 Paper Jam after attempted feed but 
before envelopes are put in the hopper OR the operator panel 
continues to display "Load Envelopes" after envelopes are placed 
in the hopper. 

Service Tip: The kick rolls rotate during the attempted feed cycles. 





FRU 


Action 


1 


Envelope Out Hopper 
Sensor Flag 


Check the envelope out sensor flag 
for damage, correct installation and 
operation. If incorrect, repair or 
replace the flag. 


2 


Envelope Out Hopper Input 
Sensor 


Check the sensor to make sure it is 
installed correctly and the sensor 
cable is properly connected to the 
envelope system board. If correct, 
perform the Envelope Feed Sensor 
Test to check both the sensor and 
flag. If the test fails, remove any 
envelopes in the hopper, turn the 
printer off and disconnect J3 from 
the system board. Turn the printer on 
and check the voltage at J3-3 on the 
system board. The voltage 
measures approximately +5 V dc. If 
incorrect, replace the envelope 
system board. If correct, replace the 
input sensor assembly. 



Diagnostic Information 2-41 



4069-XXX 

990 Service Error, Envelopes fail to feed from the hopper. 





FRU 


Action 


1 


D.C. Feed Motor Assembly 


Check the motor and motor cable for 
any signs of loose wires or poor 
connections. Check to make sure 
the motor cable is connected to the 
envelope system board. 


2 


Envelope Feeder System 
Board 


Check the voltage on J4-1 . The 
voltage measures approximately 
+24 V dc. If incorrect, replace the 
envelope system board, if correct, 
measure the voltage at J4-6. The 
voltage measures approximately 
+5 V dc. If incorrect, disconnect J4 
and measure the voltage again. If 
incorrect, replace the envelope 
feeder system board. If correct, 
replace the D.C. motor assembly. 



260 Paper Jam displays, unable to clear and envelopes fail to feed 
from the hopper. Kick rolls ARE NOT rotating. 





FRU 


Action 


1 


Main Drive Belt 


Check the belt for correct installation 
and for signs of damage. Replace as 
necessary. 


2 


Gears 


Check all the gears for correct 
installation and for signs of damage. 
Repair or replace parts as 
necessary. 


3 


Clutch Latch Assembly 


Check the clutch latch assembly to 
make sure it moves freely. 


4 


Master Cam Gear Master/ 
Kick Gear 


Check the master cam gear and 
master/kick gear to make sure they 
rotate together. If not, then the 
tenons on the master kick gear may 
be sheared off. If incorrect, replace 
the master kick gear. 



2-42 Service Manual 



4069-XXX 

260 Paper Jam displays, unable to clear and envelopes fail to feed 
from the hopper. Kick rolls ARE rotating. 

Check the deflector gap adjustment before continuing this service 
check. 





FRU 


Action 


1 


Deflector Gap Adjustment 


Check the deflector gap adjustment. 
The adjustment may be too narrow. 


2 


Weight Assembly 


Check the weight assembly to make 
sure it moves up and down freely 
without any binds. Also check to 
make sure the weight assembly 
rests on all the rear kick rollers when 
the hopper is empty. Replace the 
weight assembly if it is damaged or 
does not operate properly. 


3 


Envelope Edge Guide 


Check the envelope edge guide to 
make sure it is not warped or set too 
close to the envelopes in the hopper. 
Replace the edge guide if it is 
damaged or does not operate 
properly. 



Diagnostic Information 2-43 



4069-XXX 

260 Paper Jam displays, envelope stops in feeder paper path. 





FRU 


Action 


1 


Kick Rolls/Feed Rolls/Drive 
Rolls 


Check all the rolls for any signs of oil, 
grease or other contamination. If you 
find a problem, clean the rolls. If this 
does not correct the problem, 
replace the envelope feeder option. 


2 


Deflector Gap Adjustment 


Check the deflector gap adjustment. 
The adjustment may be too narrow. 



Envelope Feeder multifeeds or may not display a 260 Paper Jam 
message. 





FRU 


Action 


1 


Envelopes 


Check the envelopes being used in 
the feeder. Check for signs of the 
envelopes being stuck together or 
signs of glue. Check to make sure 
the flaps are not interleaved. 


2 


Deflector 


Check the deflector gap adjustment. 
The adjustment may be too wide. 


3 


Restraint Roll Bias Spring 


Check for a missing, broken or 
incorrectly installed restraint roll bias 
spring. If incorrect, reinstall or 
replace the spring. 



260 Paper Jam displays. An envelope stopped in the paper path of 
the feeder and an envelope also stopped in the base printer paper 
path. 





FRU 


Action 


1 


Latch Lever 


Check to make sure the tip of the 
latch lever is centered in the opening 
in the floor of the paper path. The 
latch lever may not be detented on 
the latch. 



2-44 Service Manual 



4069-XXX 

Erase Lamp Service Check (01 0/21 2/41 4/61 6/31 v/01 n/ 
21n/31e/41n/61n) 

Error code 928 may be displayed when the printer detects that the 
erase lamp assembly, cable or engine board is defective. 

Note: If the erase lamp assembly is defective, both the erase lamp 
and lens are replaced as a kit. Models 41 b/41 e/41 1 and any model at 
service level B do not have erase lamps installed. Go to "Printer 
Serial Label" on page 7-2 to identify the printer service level. 

Make the following checks when a 928 service error displays. 





FRU 


Action 


1 


Cable, Front Harness 


Check the connection of the front 
harness to connector J1 on the 
engine board for correct installation. 
If incorrect, repair as necessary. 
Check the front harness to erase 
lamp assembly for correct 
installation. If incorrect, repair as 
necessary. 


2 


Engine Board 


Remove the controller board and 
toner cartridge from the machine. 
Ground pin J1 0-1 5. The erase lamps 
turn on. The lamps can be observed 
through the front of the machine with 
the cover open and print cartridge 
removed. If the lamps do not turn on, 
measure the voltage on J1 0-1 4. The 
voltage reads approximately 
+24 V dc. If incorrect, replace the 
engine board. If correct, check the 
voltage at J1 0-15. The voltage reads 
between +1 5 V dc to +20 V dc. If 
incorrect, check the continuity of the 
erase lamp lines in the main 
harness. If incorrect, replace the 
cable harness. If correct, replace the 
erase lamp assembly. 



Diagnostic Information 2-45 



4069-XXX 

Fan Service Check 

Auxiliary Fan Service Check 

The auxiliary fan is in models 41 4/61 6/41 1/61 n. 
Fan does not run or is noisy. 





FRU 


Action 


1 


Fan Assembly 


Check the fan for proper installation 
and for excessive noise. If incorrect, 
replace the fan and cable assembly. 


2 


Engine Board 


Check to make sure the auxiliary fan 
cable is seated on connector J7 on 
the engine board. If correct, check 
for +24 V dc on J7-1 on the engine 
board. If incorrect, replace the 
engine board. If correct, replace the 
fan assembly. 

Note: When the printer is in warm- 
up the voltage at J7-1 measures 
approximately +12 V dc. When the 
printer is running, the voltage 
measures approximately +24 V dc. 



Main Fan Service Check 

Check the cable connections at J1 on the engine board and at the 
main fan assembly. The main fan runs continuously when the printer 
is powered on unless the printer is in the Power Saver mode. 





FRU 


Action 


1 


Main Fan 


Manually spin the fan and check that 
it rotates freely. Check the cable 
connection to the engine board, J1 
for correct installation. 


2 


Main Fan to Engine Board 
Cable 


Check the continuity of the cable. If 
incorrect, replace the cable. 



2-46 Service Manual 



4069-XXX 





FRU 


Action 


3 


Error Code 927 (Fan runs) 


Check the voltage at J1-1 on the 
engine board. The voltage measures 
+5 V dc (static) V dc (fan running). 
If incorrect, replace the main fan. If 
this does not fix the problem, replace 
the engine board. 


4 


Error Code 927 
(Fan not running) 


Check the voltage at J 1-3 on the 
engine board. The voltages are as 
follows: 

+22 V dc to +24 V dc 
(printer and fan running) 

+12Vdcto+15 Vdc 

(printer not running - fan running 

about half speed). 

If incorrect, replace the engine 
board. If this does not fix the 
problem, replace the main fan. 



Fuser Service Check 

Hot Roll Fuser 

Cold Fuser Service Check 

Error codes 920, 921 , and 922 may display for a cold fuser failure. A 
920 error caused by low line voltage can sometimes be cleared by 
turning the machine off and then on again. A 925 service error 
indicates the wrong fuser lamp is installed in the printer and does not 
match the one stored in the printer code. 

Note: Make sure the fuser is correctly installed before proceeding 
with this service check. The fuser must be firmly seated in the two 
rear connectors. Both the right and left lock down screws must be 
tight. 

Service Tip: Set the Fuser Temperature to NORMAL before starting 
this service check. 



Diagnostic Information 2-47 



4069-XXX 





FRU 


Action 


1 


Fuser Lamp (Incorrect 
Lamp/925 Service Error) 


Install the correct voltage and 
wattage lamp or fuser assembly. 


2 


Fuser Lamp 


Remove the controller board. Run 
the Diagnostic Print Test and 
observe the lamp through the left 
side frame. If the lamp doesn't come 
on, unplug the printer and check the 
continuity between the two pins on 
the fuser lamp cable going to the 
fuser assembly. If you do not 
measure continuity, remove the fuser 
assembly and check the continuity of 
the lamp. If incorrect, replace the 
lamp. If correct, replace the fuser 
cover assembly. 


3 


LVPS 

LVPS to Fuser Auto 
Docking Connector 
Fuser AC Cable 


Turn the printer off. Remove the 
fuser assembly. Turn the printer 
power on. Measure across the AC 
fuser cable pins for line voltage with 
the cable connected. If incorrect, 
turn the printer off and disconnect 
the power cord. Check the continuity 
of the LVPS to fuser AC cable. If 
incorrect, replace the cable. If 
correct, replace the LVPS. 


4 


Fuser Top Cover Assembly 
(Thermal Fuse/Thermistor 
Assembly) 


Disconnect the thermistor cable from 
the fuser board at J2. The resistance 
is as follows: 

HOT - J2-1 - J2-2 = 2.5K ohms 

COLD = 1 50K ohms to 260K ohms 



2-48 Service Manual 



4069-XXX 

Hot Fuser Service Check 

Error codes 923 and 924 may display for a hot fuser failure. 

CAUTION: The fuser may be hot, use caution before removing or 
servicing. 





FRU 


Action 


1 


Fuser Cover Assembly 
(Assembly includes 
Thermistor and Thermal 
Fuses.) 


Check for damage to the thermistor 
assembly. Check the resistance of 
the thermistor: 

HOT - J2-1 to J2-2 = 2.5K ohms 

COLD =1 50K ohms to 260K ohms 

Check the continuity from each pin 
of J2 to ground. If there is continuity, 
replace the fuser cover assembly 


2 


Engine Board 


Error code 924 indicates the engine 
board detects an open circuit in the 
thermistor circuit for the fuser 
assembly. The voltage on J2-6 on 
the engine board measures 
approximately +5 V dc. If incorrect, 
replace the engine board. If correct, 
check the continuity of the DC fuser 
cable (fuser board to auto docking 
connector) in the fuser assembly and 
the DC fuser cable (engine board to 
auto docking connector) in the 
printer. If there is no continuity, 
replace the cable. If there is 
continuity, check the voltage on J2-2 
on the fuser control board. It 
measures approximately +5 V dc. If 
incorrect, replace the fuser control 
board. 


3 


Fuser Hot Roll 
Backup Roll Bearings 


Examine the fuser assembly for 
signs of overheating or damage. 
Check the hot roll and backup roll for 
signs of excessive toner, label glue, 
labels or other contaminants. If any 
are found, repair as necessary or 
replace the fuser assembly. 



Diagnostic Information 2-49 



4069-XXX 

Belt Fuser 

Hot Fuser Service Check 

Error codes 923 and 924 may display for a hot fuser failure. 

Note: The belt fuser assembly is a FRU. Do not attempt to 
disassemble and repair the belt fuser. 

CAUTION: The fuser may be hot, use caution before removing or 
servicing. 





FRU 


Action 


1 


Engine Board 

EP Autoconnect Cable 

(Engine Board to Fuser) 


Error code 924 indicates the engine 
board detects an open circuit in the 
thermistor circuit for the fuser 
assembly. The voltage on J2-6 on 
the engine board measures 
approximately +5 V dc. If incorrect, 
replace the engine board. If correct, 
check the continuity of the DC fuser 
cable (engine board to auto docking 
connector) in the printer. If there is 
no continuity, replace the cable. If 
there is continuity, replace the belt 
fuser assembly. 



2-50 Service Manual 



4069-XXX 

Fuser Solenoid Service Check 

The fuser solenoid is in all models except the 31 v and 31 e. 

Service Tip: Try changing the envelope enhance level setting. A 
different setting may correct the problem. 

Note: Check the fuser envelope conditioner solenoid adjustment as 
described in the adjustment section "Fuser Solenoid Adjustment" on 
page 4-3. 





FRU 


Action 


1 


Fuser Envelope Conditioner 
Solenoid 


The operation of the fuser solenoid 
can be observed by removing the 
redrive assembly. Check for proper 
mechanical operation of the solenoid 
and associated hardware, link and so 
on. If correct, check the resistance of 
the solenoid between J4-1 and J4-2. 
The resistance measures between 5 
ohms and 10 ohms. If incorrect, 
replace the solenoid assembly. 


2 


Fuser Control Board 


The solenoid receives power from the 
engine board. The fuser control board 
receives +42Vdc from the LVPS via 
the interconnect board. Check for 
approximately +42 V dc at the 
+42 V dc test point on the fuser control 
board. If the voltage is correct, replace 
the fuser control board. 



Diagnostic Information 2-51 



4069-XXX 





FRU 


Action 


3 


LVPS 
Interconnect Board 


If the +42 V dc test point does not 
measure approximately +42 V dc, 
check the voltage at CN3-1 8 on the 
LVPS. The voltage measures 
approximately 

+42 V dc. If the voltage is correct, 
replace the interconnect board 
assembly. If the voltage is incorrect, 
replace the LVPS. 


4 


Fuser DC Cable (Engine 
Board to Fuser Board Cable) 
Engine Board 


Check for continuity of the DC fuser 
cable that is attached between J2 on 
the engine board and J1 on the fuser 
control board. If the cable does not 
measure continuity, replace the cable. 
If the cable measures continuity, 
replace the engine board. 



Input Sensor Service Check 

Service Tip: Run the Base Sensor Test. Check the input sensor for 
proper operation. The display changes from open to closed as the 
sensor flag is manually moved in and out of the sensor. 

Service Tip: Run a Diagnostic Print Test in the continuous mode with 
the controller board removed. A defective input sensor or circuit 
causes the first copy to exit only partially through the fuser assembly. 





FRU 


Action 


1 


Input Sensor Flag 


Check the input sensor flag for 
damage and proper operation. If a 
problem is found, repair as 
necessary. 


2 


Engine Board 


Check for approximately +5 V dc at 
J10-10 on the engine board. If 
incorrect, replace the engine board. 



2-52 Service Manual 



4069-XXX 





FRU 


Action 


3 


Input Sensor Cable 


Check the continuity of the input 
sensor cable section of the front 
wiring harness. If incorrect, replace 
the harness. If correct, replace the 
input sensor assembly. 



Input Tray(s) Option Service Check 

250 Sheet and 500 Sheet Trays 

Service Tip: Try all the other input paper sources to make sure they 
are properly feeding paper. 

For 990 Error Code- Service Tray X, X= displays the number of the 
tray that has a problem or needs service. 





FRU 


Action 


1 


Tray X option System Board 
or Compensator Assembly 
or Autoconnect Cable 


Check the autoconect cables and 
connectors for any signs of damage. 
Replace if necessary. Check the 
cables for continuity. If incorrect, 
replace the compensator assembly 
cable. If the cables, connectors and 
connections are good, replace the 
FRUs in the following order: 

autocompensator assembly option 

system board 



Diagnostic Information 2-53 



4069-XXX 

24X Paper Jam message displays, Paper jammed over the Pass 
Thru Sensor. (The printer displays the value of X for the paper tray 
where the error occurs. Example: 241 is a Paper Jam Tray 1) 





FRU 


Action 


1 


Pass Thru Sensor and Flag 
Assembly 


The tray x option system board did 
not detect a piece of paper actuating 
the pass thru sensor. Remove any 
jammed sheets of paper from the 
printer and check the pass thru 
sensor and flag for proper operation 
by running the appropriate Tray 
Sensor Test from the diagnostics 
menu. If the test fails, check the 
sensor for correct installation and the 
flag for proper operation. Also check 
the sensor cable to make sure it is 
correctly connected to the option 
system board. If incorrect, replace 
the tray x option pass thru sensor 
assembly. 


2 


Power Takeoff Shaft and 
Spring, Bevel Gear, 
Feedroll Gear, Drive Roll 
Assembly, Wear Plate, 
Drive Shaft Bearings and 
Skewed Backup Roller 


Check these parts for signs of 
broken or damaged parts, 
contamination on the drive rollers or 
wear plate and wear or damage to 
the drive shaft bearings. Check the 
drive roll assembly and skewed 
backup roller for signs of wear, slick 
spots, material buildup, and oil or 
grease on the rollers. Also check for 
proper operation of the paper 
aligning assembly. Repair or replace 
parts as necessary. 



2-54 Service Manual 



4069-XXX 

Tray X Low message displays when Tray X is full or has adequate 
paper in the tray. 





FRU 


Action 


1 


Paper Low Sensor 

Assembly 

Paper Low Sensor Flag 

Tray X Option System 

Board 


Run the Tray X Sensor Test and 
check the sensor for proper 
operation. If incorrect, check the 
following: 

Paper low sensor flag for smooth 
and correct operation. 

Paper low sensor for correct 
installation on the autocompensator 
housing. 

Paper low sensor cable for signs of 
cuts, pinched wiring or other 
damage especially at connector J5 
on the system board. 

If no problem is found, replace the 
paper low sensor assembly. If this 
does not correct the problem, 
replace the option system board. 



Tray X Empty message displays when Tray X has paper in the tray. 





FRU 


Action 


1 


Paper Out Sensor Flag 


Check the paper out sensor flag for 
correct operation and installation. If 
correct, replace the option system 
board. (The paper out sensor is 
mounted on the system board). 


2 


Paper Out Sensor (On 
Option System Board) 



Diagnostic Information 2-55 



4069-XXX 

Printer does not recognize Tray X is installed. 





FRU 


Action 


1 


Autoconect Cables 
Tray X System Board 


Check the autoconnect from the 
printer or option above tray x. Check 
for signs of cuts, pinched wiring or 
damage to the contacts in the 
connector. Check the autoconnect 
cable(s) for correct installation at the 
tray x system board. If correct, check 
the continuity of the autoconnect 
cable(s). If correct, replace the tray x 
system board. If incorrect, replace 
the cable. 



Paper from Tray X does not reach the Pass Thru Sensor. 

Service Tip: Check the media in tray x to make sure it is within 
specifications. Some types of labels, foil material and slick papers 
can cause misfeeds and slippage of the rollers. 





FRU 


Action 


1 


Autocompensator 
Assembly 


Check the autocompensator pick 
arm rollers for any sign of glazing, 
toner or other buildup. Clean or 
replace as necessary. 



High Capacity Feeder Input Tray Service Check 

Note: Voltage measurements in the high capacity feeder input tray 
service checks must be made with the high capacity feeder attached 
to the base printer to obtain accurate results. 

Service Tip: Be sure the paper size switch is set to the correct paper 
size setting and the rear paper guides are in the correct locations for 
the size of paper installed in the high capacity feeder tray. 

Service Tip: Check the other paper sources to be sure they are 
operating correctly. 



2-56 Service Manual 



4069-XXX 

The base printer indicates a dead machine condition when the 
high capacity input tray is installed. 





FRU 


Action 


1 


AC Line Cord 

AC Jumper (HCIT to 

Printer) 

AC input and Output 

Receptacles 

AC Wiring Harness 


If the base printer works normally 
using the AC line cord from the AC 
wall outlet and does not work when 
using the AC jumper from the HCIT, 
check the AC jumper cord. If 
defective, replace the cord. If not 
defective, check the AC input and 
output receptacles and wiring 
harness in the HCIT. Repair or 
replace the receptacles or AC wiring 
harness as required. 

NOTE: Make sure the ground wire is 
installed correctly from the AC wiring 
harness to the frame of the HCIT 
and the nut and lockwasher are 
tightened down. 



Diagnostic Information 2-57 



4069-XXX 

The base printer does not recognize that the high capacity input 
tray is installed. 





FRU 


Action 


1 


High Capacity Feeder 
Autoconnect Mechanical 
Check 


Check the high capacity feeder input 
tray to make sure it is mounted 
correctly and is not pushed down 
into the frame assembly or 
damaged. Be sure the high capacity 
feeder input tray autoconnect is 
properly connected to the high 
capacity feeder tray option board 
assembly. 


2 


Base Printer or option 
mounted above 


Check the option or base printer 
autoconnect for signs of damage. 
Repair the high capacity option 
autoconnect as necessary. 


3 


LVPS (2000 Sheet Option) 
Option System Board 


Check the voltages at J1 1 -2 and 
J1 1-4. The voltage measures 
+24 V dc, If the voltage is correct, 
replace the high capacity system 
board assembly. If the voltage is 
incorrect, check the continuity of the 
AC input cable to the LVPS. If 
correct, replace the LVPS assembly. 
If incorrect, replace the AC cable to 
the input of the LVPS. 



2-58 Service Manual 



4069-XXX 



FRU 



Action 



High Capacity Feeder 
Option Control Board 



Check the voltage on J8-1 (green). 
The voltage measures +24 V dc. If 
incorrect, check the autoconnect 
system for any problems. +24 V dc 
must come from the base printer 
through the autoconnect system to 
the high capacity input for the high 
capacity feeder to be recognized. If 
the voltage is correct, check the 
voltages at J1 1 -3(red) and J1 1 - 
4(red). The voltages measure +24 V 
dc. If correct, replace the high 
capacity feeder option system board. 
If incorrect, disconnect J8 from the 
system board and measure the 
voltages again. If incorrect, check 
the LVPS cable and the A.C. internal 
wiring from the input appliance 
receptacle. If incorrect, replace as 
necessary. If correct, replace the 
LVPS. If the voltages are correct, 
check the stepper motor for shorts 
from the motor housing to each pin 
on the motor connector. If you find a 
short between any pin and the motor 
housing, replace the motor 
assembly. If no shorts are found, 
replace the high capacity feeder 
option control board. 

Check the voltage at J9-1 (light 
blue). The voltage measures 
approximately +24 V dc. If incorrect, 
disconnect the cable at J9 and check 
the voltage again. If the voltage 
continues to be incorrect, replace 
the high capacity feeder option 
system board. If the voltage 
measures correctly, check the cable. 
If the cable is damaged, replace as 
necessary. If no problem is found 
with the cable, replace the high 
capacity feeder option control board. 



Diagnostic Information 2-59 



4069-XXX 

24X Paper Jam message displays, Paper jammed over the Pass 
Thru Sensor. (X=The printer displays the value of X for the paper 
tray where the error occurs. Example: 242 is a Paper Jam Tray 2) 





FRU 


Action 


1 


Pass Thru Sensor and Flag 
Assembly 


The tray x option system board did 
not detect a piece of paper actuating 
the pass thru sensor. Remove any 
jammed sheets of paper from the 
printer and check the pass thru 
sensor and flag for proper operation 
by running the appropriate Tray 
Sensor Test from the diagnostics 
menu. If the test fails, check the 
sensor for correct installation and the 
flag for proper operation. Also check 
the sensor cable to make sure it is 
correctly connected to the option 
system board. If incorrect, replace 
the tray x option pass thru sensor 
assembly. 


2 


Power Takeoff Shaft and 
Spring, Bevel Gear, 
Feedroll Gear, Drive Roll 
Assembly, Wear Plate, 
Drive Shaft Bearings and 
Skewed Backup Roller 


Check these parts for signs of 
broken or damaged parts, 
contamination on the drive rollers or 
wear plate and wear or damage to 
the drive shaft bearings. Check the 
drive roll assembly and skewed 
backup roller for signs of wear, slick 
spots, material buildup, and oil or 
grease on the rollers. Also check for 
proper operation of the paper 
aligning assembly. Repair or replace 
parts as necessary. 



2-60 Service Manual 



4069-XXX 

Tray X Paper Low Message displays when Tray X is full or has 
adequate Paper in the tray. 





FRU 


Action 


1 


Paper Low Switch 
Paper Low Switch Cable 
High Capacity Feeder Input 
System Board 


Run the sensor diagnostics for tray X 
(X=the number that represents the 
high capacity input tray). If the test 
fails, disconnect the paper low switch 
cable from J3 on the high capacity 
system board. Short pins 1 and 2 
together while observing the sensor 
test on the display. If the display 
does not change, replace the high 
capacity feeder system board. If the 
display changes check the continuity 
of the switch. If incorrect, replace the 
switch. If correct, replace the switch 
cable. 



Tray X empty message displays when there is paper in the high 
capacity feeder input tray. 





FRU 


Action 


1 


Paper Out Sensor Flag 


Check the paper out sensor flag for 
correct operation and installation. If 
correct, replace the high capacity 
feeder system board. (The paper out 
sensor is mounted on the high 
capacity feeder system board). 


2 


Paper Out Sensor 

(On Option System Board) 



Diagnostic Information 2-61 



4069-XXX 

The elevator tray fails to stop at the correct position and continues 
to drive into the bottom frame. 





FRU 


Action 


1 


Lower Limit Switch 
Lower Limit Switch Cable 


Check continuity of the lower limit 
switch. If incorrect, replace the 
switch. If correct, check the switch 
cable. If incorrect, replace the cable. 
If correct, replace the high capacity 
feeder option control board. 


2 


High Capacity Feeder 
Control Board 


Disconnect the lower limit switch 
cable and check the voltage at J2-1 
(orange). The voltage measures 
approximately +5 V dc. If incorrect, 
replace the high capacity feeder 
option control board. 



The elevator tray down button does not operate. The tray moves to 
the upper position. 

Service Tip: Open the high capacity feeder option front door and 
check the black rubber bumper attached to the door switch spring. 
Be sure the rubber button is centered and not touching the sides of 
the hole or the switch will not function properly. 





FRU 


Action 


1 


Lower Limit Switch 


Check the lower limit switch to make 




Lower Limit Switch Cable 


sure it is not closed (normally open). 




High Capacity Feeder 


If incorrect, replace the switch. 




Control Board 


Check the lower limit switch cable for 
a short between pins 1 and 2. If 
incorrect, replace the cable. If 
correct, replace the high capacity 
feeder option control board. 



2-62 Service Manual 



4069-XXX 

Paper from the high capacity feeder input tray does not reach the 
pass thru sensor. 

Service Tip: Check to be sure the paper in tray is within 
specifications. 





FRU 


Action 


1 


Autocompensator 
Assembly 


Check the autocompensator pick 
arm rollers for sign of glazing, toner 
or other buildup. Replace as 
necessary. 


2 


Wear Strips 


Check the wear strips for glazing or 
contamination. Replace as required. 
It is advisable to replace all four wear 
strips at the same time. 



Diagnostic Information 2-63 



4069-XXX 

The elevator tray does not move up or down. The printer 
recognizes that the option is installed. 





FRU 


Action 


1 


DC Drive Motor High 
Capacity Feeder Option 
System Board 


Be sure the motor cable is correctly 
installed at J1 on the board. Check 
the cables, damaged or loose wires. 
Disconnect the motor. Check for a 
short between each pin and the 
motor housing. If a problem is found, 
replace the motor assembly. If no 
problem is found, measure the 
resistance between the following 
pins on the motor cable connector: 

Pins 1 (brown) and pin 2 (Yellow) 

The resistance measures between 
approximately 7.5 and 10.5 ohms. If 
incorrect, replace the motor 
assembly. If correct, replace the high 
capacity feeder option system board. 



2-64 Service Manual 



4069-XXX 

The elevator moves in one direction only. 





FRU 


Action 


1 


DC Drive Motor 
Assembly High 
Capacity Feeder 
System Board 


Check the voltages at J1 on the high 
capacity system board. The voltages 
measure as follows: 

Static (Motor Not Running) 

J1-1 (Brown): approximately V dc 

J1-2 (yellow): approximately OV dc 

Motor Running Forward 

J1-1 (Brown): Approximately V dc 

J1-2 (Yellow): Approximately +24V dc 

Motor Running Reverse 

J1-1 (Brown): Approximately +24 V dc 

J1-2 (Yellow): Approximately V dc 

If any of the voltages are incorrect, 
disconnect the motor and measure the 
resistance between J-1 and J-2. The 
resistance measures between 7.5 and 10.5 
ohms. If incorrect replace the motor. If 
correct, replace the system board. 



Diagnostic Information 2-65 



4069-XXX 

Paper size switch not selecting paper size that is selected. 





FRU 


Action 


1 


Paper Size Switch 
High Capacity Feeder 
Option Control Board 


Check for continuity between the 
common pin (J5-1 ) and the pin of the 
paper size selected. 

J5-1 (Black): Common Lead 

J5-2 (Blue)B5 

J5-3 (Green) Executive 

J5-4 (Yellow) A4 

J5-5 (Orange) Letter 

J5-6 (Red) Legal 

J5-7 (Brown) A5 

If any position does not measure 
continuity when selected, replace 
the paper size switch assembly. If 
the switch assembly is operating 
correctly, replace the high capacity 
feeder option control board. 



24X Paper Jam Check Tray X Message displays when Tray X is 
empty. No Tray X Message displays. 





FRU 


Action 


1 


High Capacity Feeder 
Option Control Board 


Check the voltages on the board at 
J4-1(red) and J4-3 (blue). The 
voltages measure approximately 
+5 V dc. If incorrect, disconnect J4 
from the board and measure the 
voltages again. If incorrect, replace 
the high capacity feeder option 
control board. 


2 


Elevator Top Optical 
Sensor Cable 
Elevator Top Optical 
Sensor 


Check the continuity of the sensor 
cable. If incorrect, replace the cable. 
If correct, replace the top optical 
sensor assembly. 



2-66 Service Manual 



4069-XXX 

Tray X Empty message displays. Tray does not respond to loading 
paper. No response from the front door switch. 





FRU 


Action 


1 


High Capacity Feeder 
Option Control Board 


Check the voltage on the board at 
J4-2 (green). The voltage measures 
approximately +5 V dc. If incorrect, 
disconnect the cable at J4 and check 
the voltage again. If incorrect, 
replace the high capacity feeder 
option control board. 


2 


Elevator Top Optical 
Sensor Cable 
Elevator Top Optical 
Sensor 


Check the continuity of the sensor 
cable. If incorrect, replace the cable. 
If correct, replace the top optical 
sensor assembly. 



Tray X Paper Low Message displays when the high capacity feeder 
input tray is full or has adequate paper in the tray. 





FRU 


Action 


1 


Paper Low Switch 
Paper Low Switch Cable 
High Capacity Feeder 
Option Control Board 


Run the sensor diagnostics for tray X 
(X=the number that represents the 
high capacity input tray). If the test 
fails, check the voltage at J3-1 
(grey). The voltage measures 
approximately +24 V dc. If incorrect, 
disconnect the paper low switch 
cable from J3 and measure the 
voltage again on J3-1 . If incorrect, 
replace the high capacity feeder 
option control board. If correct, 
check the cable for a short between 
pins 1 and 2 on the cable. If 
incorrect, replace the cable. If 
correct, check the switch for a bent 
or deformed actuator lever or 
defective switch. If incorrect, replace 
the switch. 



Diagnostic Information 2-67 



4069-XXX 

Excessive Noise or Vibration 





FRU 


Action 


1 


DC Motor Assembly 


Check to make sure all the motor 
plate mounting screws are tight. 


2 


Idler Pulley 

DC Motor Assembly 


Check to make sure the idler pulley 
is not binding on the pulley shaft. 
Check the pulley for any signs of 
wear. Check the idler pulley shaft on 
the motor mounting plate for any 
signs of damage or contamination. 


3 


Drive Pulley 


Check the drive pulley for any signs 
of wear, binds or damage to the 
pulley or pulley shaft. Make sure the 
pulley turns freely on the pulley 
shaft. 


4 


Motor Drive Belt 
Tray Drive Belt 


Check the DC motor drive belt for 
any signs of damage. Check to make 
sure the belt is tracking correctly on 
the drive pulley, idler pulley and 
motor pulley. Check the tray drive 
belt for any signs of damage. Check 
to make sure the belt is tracking 
correctly on the lower section of the 
drive pulley and lead screw pulleys. 



2-68 Service Manual 



4069-XXX 

Main Drive Service Check 

Service Tip: Excessive gear or main drive assembly noise is usually 
caused by a defective motor assembly or engine board. 

Service Tip: If there are equally spaced horizontal lines across the 
page, go to "Print Quality - Evenly spaced horizontal lines or marks" on 
page 2-97. 

WARNING: Whenever the gearbox assembly is removed from the 
machine it must be handled very carefully. Do not allow any of the 
gears to come in contact with any metal or other hard surface to 
avoid gear damage. It is also very important not to let any dirt, paper, 
staples or other material come intact with the grease in the gearbox 
assembly. 





FRU 


Action 


1 


Main Drive Assembly 
(Excessive noise or 
vibration) 


Remove the controller board and run 
a Diagnostic Print Test in the 
continuous mode. Check the main 
drive assembly for any excessive 
noise or vibration. Determine if the 
noise is in the main drive, toner 
cartridge, fuser or main drive 
gearbox. Look for any loose or worn 
parts in the developer drive 
assembly, main drive gearbox or 
fuser. Repair as necessary. 


2 


Main Drive Motor Assembly 
(Excessive noise, gears 
ratcheting and so on) 


A service error code 936 - Transport 
Motor may be displayed. Check the 
voltage at J1 2-6 on the engine 
board. It measures approximately 
+5 V dc when the motor is not 
running and goes to V dc when the 
motor is running. If incorrect, replace 
the engine board. If this does not fix 
the problem, replace the main drive 
motor. 


3 


Main Drive Motor Cable 


Check the continuity of the main 
drive motor cable. If incorrect, 
replace the cable. 



Diagnostic Information 2-69 



4069-XXX 





FRU 


Action 


4 


Motor does not turn, no 
gear error code 936 or User 
message 201 Paper Jam 
displays. 


Check the voltages at J12 on the 
engine board. 

Pin number and voltage: 

J12-1 =+24Vdc 

J1 2-4 = +5 Vdc (static) OVdc 
(when main drive motor running) 

J12-5 = + 5 Vdc (static) OVdc 
(when main drive motor running) 

J12-6 = +5 V dc (static) +2.5 V dc 
(when main drive motor running) 

J1 2-7 = +5 Vdc (static) OVdc 
(when main drive motor running) 

J 1 2-8 = +5 V dc (static) +5 V dc 
(when main drive motor running) 

J12-11 = + 5 V dc (static) V dc 
(when main drive motor running) 

If the voltage is incorrect, replace the 
FRUs in the following order: 

main drive motor assembly 

engine board 



Operator Panel Service Check 

Operator Panel Buttons Service Check 

Note: Before continuing with this service check do the "Button Test" 
on page 3-9 in the diagnostic aids chapter. 





FRU 


Action 


1 


Operator Panel Assembly 


If any button fails the Button Test, 
replace the operator panel assembly. 



2-70 Service Manual 



4069-XXX 





FRU 


Action 


2 


Engine Board 
(No buttons work) 


Check the voltage at J1 1-5. The 
voltage measures approximately 
+5 V dc with the controller board 
removed. If incorrect, replace the 
engine board. If correct, check the 
continuity of the operator panel 
cable. If incorrect, replace the cable. 
If correct, replace the operator panel 
assembly. 



Operator Panel Display Service Check 

SERVICE TIP: The printer has detected a problem with the engine 
board, operator panel cable or operator panel assembly if POST 
does not complete and the printer emits 5 beeps and stops in a 
continuous pattern until the printer is turned off. The operator panel 
cable is an individual cable on some printers and a combination 
cable assembly with the cover switch cable on later models. 

Note: If the operator panel is operating properly except for a PEL or 
a few PELS missing or broken, run the "LCD Test" on page 3-9 from 
the hardware tests before continuing with this diagnostic service 
check. 





FRU 


Action 


1 


Operator Panel Cable 


Check for proper installation of the 
cable at the engine board (J1 1 ) and 
at the operator panel. Check the 
continuity of the operator panel 
cable. If incorrect, replace the cable. 


2 


Operator Panel Display 
blank, 5 beeps, LED Off 


Check the voltage at J1 1-2 on the 
engine board. It measures 
approximately +5 V dc. If incorrect, 
replace the engine board. If correct, 
replace the operator panel assembly. 


3 


Operator Panel Display 
blank, 5 beeps, LED On 


Check for ground between J1 3-4 and 
ground. If correct, replace the 
operator panel assembly. If incorrect, 
replace the engine board. 



Diagnostic Information 2-71 



4069-XXX 





FRU 


Action 


4 


Operator Panel all 
diamonds, No Beeps 


Check to make sure a SIMM is not 
plugged in backward. This condition 
causes the printer to fail POST 
displaying all diamonds on the 
operator panel with no beeps. 


5 


Operator Panel all 
diamonds, 5 Beeps 


Check the voltage at Pin J1 1-1 and 
J1 1 -3. The voltage measures 
approximately +5 V dc. If incorrect, 
replace the FRUs in the following 
order: 

operator panel assembly 

engine board 



Options Service Check 

Service Tip: When you have a problem with any of the options 
installed in the options slots on the interconnect board on a 212/414/ 
61 6/01 n/21 n/41 n/61 n (the 01 0/31 v/31 e and 01 at service level B 
have only one slot), switch the non operating option to one of the 
other option slots to isolate the failure. 

Flash Memory Option(s) 

Run a copy of the test page and check to see if the option you are 
checking is listed. The printer does not recognize the option being 
installed if the option is not listed. Check to make sure that the 
Memory DIMM is installed correctly and is not broken or damaged. If 
the Memory DIMM is correctly installed not broken or damaged then 
run the "Flash Test" on page 3-3. If the test fails, replace the FLASH 
DIMM. If the problem continues, replace the controller board. 

DRAM Memory Option(s) 

This service check is the same as the flash memory option service 
check with the following exception: 

Run the "SDRAM Memory Test" on page 3-10 from the menu if the 
SDRAM Memory DIMM is correctly installed and not broken or 
damaged. If the test fails, replace the SDRAM DIMM. If the problem 
continues, replace the controller board. 



2-72 Service Manual 



4069-XXX 

Hard Disk Option 

Service Tip: The Optra T printers support one hard disk option. 
Check to make sure only one hard disk option is installed. 

• 2.1 GB or larger 

Check to make sure the fixed disk and the fixed disk board are 
correctly installed. Run the "Quick Disk Test" on page 3-2 from the 
Device Test on the Diagnostic Menu when a problem is suspected 
either with the hard disk system board or with the hard disk. 

Note: The Quick Disk Test is a non-destructive test and indicates 
Pass or Fail. If the test fails, replace the hard disk. If a problem still 
exists, replace the hard disk board. 

The "Disk Test/Clean" on page 3-2 is used to help restore the disk if the 
disk contains bad data and is unusable. This test is divided into a 
cleaning and a verifying or testing section. 

WARNING: This can be a very lengthy test depending on the disk 
size. This test leaves the hard disk unformatted. The servicer or user 
must reformat the disk using the Format Disk Menu operation. This 
is a destructive type of test. All the data on the disk is destroyed and 
should not be performed on a known good disk. 

Network Card Option 

Note: The network is installed on the controller board on network 
model printers. 

Error Code 976 - Network Card X (X=Network card 1, 2, or 3) 

A 976 error code indicates an unrecoverable software error in 
network card x. Verify that network card x is correctly installed in the 
socket on the interconnect board and is properly grounded. If you 
find no problem, contact your next level of support before replacing 
the network card. 

Error Code 977 - Network Card X 

A 977 error displays when the RIP software detects that a network 
card is installed in slot x on the interconnect board but cannot 
establish communications with the network card. 



Diagnostic Information 2-73 



4069-XXX 

Output Bin Sensor Standard Tray Service Check 

Service Tip: If the output bin standard tray fills up and the bin full 
sensor fails to post the message "Remove Paper Standard Bin", 
enter the Diagnostic Mode, select Output Bin Tests, select Sensor 
Tests and select Standard Bin. Check the sensor and flag for proper 
operation. If you find no problem with the sensor and flag, continue 
with the service check. 

Service Tip: Check to make sure the correct flag is installed. The 
Output Bin Sensor is a normally closed sensor with the sensor flag 
down. Therefore, unless the flag is in the up position or out of the 
sensor slot, a Remove Paper Standard Bin message is not 
displayed. 





FRU 


Action 


1 


Engine Board 

Printer fails to display 
Remove Paper Standard 
Bin message. Output Bin 
Sensor Test fails 


Check the voltage at J6-3. It 
measures +5 V dc when the flag is in 
the sensor and V dc when the flag 
is out of the sensor. If the voltage 
does not change, replace the sensor 
cable assembly. If this does not fix 
the problem, replace the engine 
board. 


2 


Output Bin Sensor Flag 


Check to make sure the correct flag 
is installed. Check the flag for 
damage or improper operation. If 
incorrect, replace the flag. 

Note: A broken or improper 
operating sensor flag causes a 
Remove Paper Standard Bin 
message to display before POST 
completes and cannot be cleared. 



2-74 Service Manual 



4069-XXX 

Output Expander Service Check 

Service Tip: The majority of the mechanical components can be 
observed during operation by removing the left, right and system 
board covers. The output expander functions without the covers 
installed. 

Note: Make sure the option is correctly installed before attempting 
to service the unit. No jumpers should be installed at connector J6 
on the output expander board. 

Problems with excessive static electricity buildup. 





FRU 


Action 


1 


Output Expander Control 
Board Cover 


Check the output expander control 
board cover to make sure the ESD 
brush ground lead is firmly attached 
to the output expander frame. Also 
check to make sure the ESD brush is 
not loose. 



Printer does not recognize one or more output expander options 
as being installed. 

Service Tip: If more than a single output expander option is installed, 
check each one to see if the printer recognizes any single option as 
being installed. If the printer recognizes any of the output expander 
options then the base printer autoconnect system is operating 
correctly and the problem is in the unrecognized expander option. 



Diagnostic Information 2-75 



4069-XXX 





FRU 


Action 


1 


Output Expander Option 


Make sure the output expander 
option is the only option that is not 
recognized by the base printer. If the 
output expander is the only option 
not recognized by the printer, 
continue with step 2. If not, check the 
autoconnects of the options not 
recognized and the interconnect 
board and cable connections. 


2 


Output Expander Assembly 
Mechanical Linkage 


Check the autoconnects for damage, 
especially the connector pins. 
Remove the left and right side 
covers. Remove the front control 
board cover. Check the cables at 
J1 A, J1 B, J2A and J2B on the 
control board to make sure they are 
attached securely and correctly. 
Remove the output expander and 
check the voltages on the output bin 
autoconnect located on the top left 
rear of the printer. Go to 
"Autoconnect - Top" on page 5-19. If 
the voltages are correct, reinstall the 
output expander unit and check the 
voltages at J1A and J1B on the 
connector. If correct, replace the 
output expander control board. If 
incorrect, replace the output 
expander assembly mechanical 
linkage. 



2-76 Service Manual 



4069-XXX 

202 Paper Jam Open Rear Door Message displays. A sheet of 
paper is jammed prior to the pass through sensor flag. 
202 Paper Jam Open Rear Door Message displays. A sheet of 
paper feeds out to the standard bin even though bin x is selected. 
Paper exits half way out of the redrive. 

Service Tip: For this type of problem check the sub error codes. 
They can help isolate the problem. 202 Paper Jam messages can 
also occur prior to the output expander pass thru sensor. 





FRU 


Action 


1 


Output Expander Drive Belt 
Drive Pulley Drive Belt 
Idler Pulley Belt Tension 
Spring 


Check to ensure the output 
expander drive belt is correctly 
installed on the drive pulley and belt 
idler pulley. Check the belt tension 
spring to make sure it is not loose or 
broken. Repair as necessary. 


2 


Mechanical Linkage 
DC Motor Assembly 


If the DC motor is functioning 
properly check the gears, clutch and 
other linkage parts for correct 
operation and any signs of wear, 
broken gear teeth or damaged parts. 
If incorrect, replace the mechanical 
linkage/DC motor assembly. 



Diagnostic Information 2-77 



4069-XXX 

Remove Paper - Output Bin X is displayed, POST Incomplete, 
Unable to clear the message. 





FRU 


Action 


1 


Dual Output Bin Sensor Flag 


Check the flag for correct 
operation, binding, broken parts or 
interference from the sensor 
cable, If incorrect, repair as 
necessary. 



271 Paper Jam - Check Bin X. POST Incomplete 





FRU 


Action 


1 


Pass Thru Sensor and Flag 

Assembly 

Control Board 


Check the sensor flag for proper 
operation. If correct, check to 
make sure the pass thru sensor 
cable is correctly connected to J3 
on the control board. Disconnect 
the pass thru sensor cable from J3 
on the control board and check 
the voltage at J3-3. The voltage 
measures approximately +5 V dc. 
If incorrect, replace the control 
board. If correct, check the voltage 
at J3-2. The voltage measures 
approximately V dc. If incorrect, 
replace the sensor assembly. If 
this does not fix the problem, 
replace the control board. 



271 Paper Jam - Check Bin X, POST Complete, First Sheet of paper 
feeds into Output Bin X. 

Note: Before performing the following checks run the Output Bin X 
Sensor Test and check for the failing sensor. 

Sensor Test: NF = Near Full (Upper part of sensor assembly) 
F = Full (Lower Part of sensor assembly) 
P = Pass Thru Sensor 



2-78 Service Manual 



4069-XXX 

990 Service - BIN X 





FRU 


Action 


1 


D.C. Motor 
Mechanical Linkage 
Assembly 


Check the DC motor cable 
connector to be sure it is correctly 
installed at J4 on the output 
expander option board. If correct, 
disconnect J4 from the option 
board and check the resistance of 
the motor on the cable connector: 
J4-1 to J4-2: measures between 
1 1 5 and 1 35 ohms. Also check J4- 
1 and J4-2 to the motor case for 
shorts. If either the resistance is 
incorrect or a short is found, 
replace the motor/mechanical 
linkage assembly. 
Note: If the DC motor is shorted, it 
may also be necessary to replace 
the control board. 


2 


Output Expander Control 
Board 


Disconnect the motor cable J4 
and check the voltages at J4 on 
the board. 

Note: Use caution not to short to 
adjacent pins on the connector. 

J4-1 (Motor Idle) +24 V dc 
J4-2 (Motor Idle) +24 V dc 
J4-5 (Motor Idle) +5 V dc 
J4-6 (Motor Idle) +5 V dc 

If any of the voltages are incorrect, 
replace the control board. If the 
voltages are correct, replace the 
DC motor/mechanical linkage 
assembly. 



Diagnostic Information 2-79 



4069-XXX 

No indication that Bin X is Full OR No indication that Bin X is Near 
Full 





FRU 


Action 


1 


Dual Output Bin X Sensor 

Assembly 

Control Board 


Check for correct installation of 
the sensor cable at J5 on the 
control board. If either the Bin Full 
(F) or Bin Near Full (NF) fail the 
sensor test then check the voltage 
at J5-3 and J5-4. The voltage 
measures approximately +5 V dc. 
If the voltage is incorrect, replace 
the control board. If correct, 
replace the sensor assembly. 



High-Capacity Output Stacker Service Check 

Service Tip: The majority of the mechanical components can be 
observed during operation by removing the left, right and front 
covers. The high capacity output stacker option functions without the 
covers installed. 

Models 010 and 01 On do not support this output option. 

Determine which paper path stacker assembly is not functioning 
properly. 

Make sure the option(s) are installed correctly and the machine is 
configured correctly before attempting to service the high-capacity 
output stacker option. 

Go to "High-Capacity Output Stacker Board" on page 5-22 to identify the 
correct jumper location at J6 for the upper and lower units. 



2-80 Service Manual 



4069-XXX 

Problems with excessive static electricity buildup 





FRU 


Action 


1 


Front Cover Assembly 


Check the front cover assembly to 
make sure the ESD brush ground lead 
is firmly attached to the high capacity 
option. Also check to make sure the 
ESD brush is not loose or damaged. 



The printer does not recognize one or more output options as 
installed 

Service Tip: If more than a single output option is installed, check 
each one to see if the printer recognizes any single option as 
installed. If the printer recognizes any of the output options, the base 
printer autoconnect system is operating correctly. The problem is in 
the unrecognized option. Continue with this service check or go to 
the service check for the failing output option. 





FRU 


Action 


1 


High Capacity Stacker 
Option 


Check the autoconnects, cables and 
connectors of the option for any signs 
of loose or damaged parts. 


2 


High-Capacity Output 
Stacker/Mechanical Linkage 
Assembly 


Remove the left and right side covers 
and check all four autoconnects for 
damage, especially the connector 
pins. Remove the output option and 
check the voltages on the standard 
output bin autoconnect located on the 
top left rear of the printer. Go to 
"Autoconnect - Top" on page 5-19. If 
the voltages are correct, reinstall the 
output option and note the positions of 
the torroids on the autoconnect cables 
on the upper and lower assemblies, 
and check the voltages on the 
autoconnects. If all voltages are 
correct and the lower assembly is 
failing, replace the lower control 
board. If the upper assembly is failing, 
replace the upper control board. If the 
voltages are incorrect, replace the 
upper or lower failing mechanical 
linkage assembly. 



Diagnostic Information 2-81 



4069-XXX 

202 Paper Jam Open Rear Door Message displays and a sheet of 
paper is jammed prior to the pass through sensor flag or 202 
Paper Jam Open Rear Door Message displays, a sheet of paper 
feeds out to the standard bin even though bin X is selected and 
paper exits half way out of the redrive assembly. 

Service Tip: For this type of problem check the "Base Printer Sub Error 
Codes" on page 2-8. They can help isolate the problem. A 202 paper 
jam message can also occur prior to the high-capacity output 
stacker pass through sensors. 





FRU 


Action 


1 


Lower Pass Thru Sensor/ 
Flag Assembly 


Check the flag for correct operation, 
binding, broken parts or interference 
from the sensor cable. If incorrect, 
repair as necessary. If correct, check 
to make sure the lower pass thru 
sensor is correctly connected to J3 on 
the lower control board. Disconnect 
the pass thru sensor cable and check 
the voltage at J3-3. The voltage 
measures approximately +5V dc. If 
incorrect, check the voltage at J3-2. 
The voltage measures approximately 
0V dc. If incorrect, replace the sensor 
assembly. If this does not fix the 
problem, replace the lower control 
board. 


2 


High-Capacity Output 
Stacker Drive belt(s), Drive 
Pulleys, Belt Idlers, and Belt 
Tension Springs 


Check to ensure the output stacker 
drive belt or the failing assembly is 
correctly installed on the drive pulley 
and belt idler pulley. Check the belt 
tension spring to make sure it is not 
loose or broken. Repair as necessary. 


3 


Mechanical Linkage/Motor 
Assembly (Upper or Lower) 


If the DC motor is functioning properly 
check the gears, clutch and other 
linkage parts for correct operation and 
any signs of wear, broken gear teeth 
or damaged parts. If incorrect, replace 
the mechanical linkage assembly/DC 
Motor Assembly. 



2-82 Service Manual 



4069-XXX 

Remove Paper - Output Bin X Full displays. You may not be able to 
clear the message. 





FRU 


Action 


1 


Dual Output Bin Sensor Flag 
(Upper Assembly) 


Check the flag for correct operation, 
binding, broken parts or interference 
from the sensor cable. If incorrect, 
repair as necessary. 



271 Paper Jam - Check Bin X. POST Incomplete 





FRU 


Action 


1 


Upper Pass Thru Sensor 
Flag Assembly Upper 
Control Board 


Check the flag for correct operation, 
binding, broken parts or interference 
from the sensor cable. If incorrect, 
repair as necessary. If correct, check 
to make sure the lower pass thru 
sensor is correctly connected to J3 on 
the lower control board. Disconnect 
the pass thru sensor cable and check 
the voltage at J3-3. The voltage 
measures approximately +5V dc. If 
incorrect, check the voltage at J3-2. 
The voltage measures approximately 
OV dc. If incorrect, replace the sensor 
assembly. If this does not fix the 
problem, replace the lower control 
board. 



5-Bin Mailbox Service Check 

Service Tip: The majority of the mechanical components can be 
observed during operation by removing the left, right side covers. 

Models 01 0/01 On and 01 0/01 n at service level B do not support this 
output option. 

Make sure the option(s) are correctly installed before attempting to 
service the unit. Be sure the option is correctly installed and the 
machine is configured correctly before attempting to service the unit. 



Diagnostic Information 2-83 



4069-XXX 

Problems with excessive static electricity buildup 





FRU 


Action 


1 


Front Cover Assembly 


Check the front cover assembly to 
make sure the ESD brush ground lead 
is firmly attached to the 5-Bin Mailbox 
frame. Also check to make sure the 
ESD brush is not loose or damaged. 



The printer does not recognize one or more output options as 
installed. 

Service Tip: If more than a single output option is installed, check 
each one to see if the printer recognizes any single option as being 
installed. If the printer recognizes any of the output options then the 
base printer autoconnect system is operating correctly and the 
problem is in the unrecognized option. Continue with this service 
check or go to the service check for the failing output option. 





FRU 


Action 


1 


5-Bin Mailbox Option 


Check the autoconnects, cables and 
connectors of the option for any signs 
of loose or damaged parts. 


2 


Mechanical Linkage 
Assembly 


Remove the left and right side covers 
and check the two autoconnects for 
damage especially the connector pins. 
Remove the output option and check 
the voltages on the standard output 
bin autoconnect located on the top left 
rear of the printer. Go to "Autoconnect 
- Top" on page 5-19. If the voltages 
are correct, reinstall the output option 
noting the position of the torroid on the 
autoconnect cable of the lower 
autoconnect. Check the voltages on 
each of the autoconnects. If the torroid 
was moved make sure to move it back 
to its original position on the cable. If 
the voltages are correct, replace the 
control board. If the voltages are 
incorrect, replace the failing 
autoconnect assembly. 



2-84 Service Manual 



4069-XXX 

271 Paper Jam - Check Bin 1 displays 





FRU 


Action 


1 


Bottom Pass Thru Sensor 
Flag Assembly 
Control Board 


Check the flag for correct operation, 
binding, broken parts or interference 
from the sensor cable. If incorrect, 
repair as necessary. If correct, check 
to make sure the bottom pass thru 
sensor is correctly connected to J5 on 
the control board. Disconnect the pass 
thru sensor cable and check the 
voltage at J5-3. The voltage measures 
approximately +5V dc. If incorrect, 
check the voltage at J5-2. The voltage 
measures approximately OV dc. If 
incorrect, replace the sensor 
assembly. If this does not fix the 
problem, replace the control board. 



274 Paper Jam - Check Bin 4 Displays 

Service Tip: When a 274 Paper Jam Check Bin 4 message displays, 
a problem exists with the top pass thru sensor assembly or the 
control board. 





FRU 


Action 


1 


Top Pass Thru Sensor 
Flag Assembly 
Control Board 


Check the flag for correct operation, 
binding, broken parts or interference 
from the sensor cable. If incorrect, 
repair as necessary. If correct check to 
make sure the top pass thru sensor is 
correctly connected to J1 1 on the 
control board. Disconnect the pass 
thru sensor cable and check the 
voltage at J1 1 -3 The voltage 
measures approximately +5V dc. If 
incorrect, check the voltage at J1 1-2. 
The voltage measures approximately 
OV dc. If incorrect, replace the sensor 
assembly. If this does not fix the 
problem, replace the lower control 
board. 



Diagnostic Information 2-85 



4069-XXX 

Ready Bin X Full message displays - May be able to clear message 
and will feed paper into Bin selected. 





FRU 


Action 


1 


Bin X Sensor 
Bin X Sensor Cable 
Bin X Sensor Flag 
Control Board 


Check the sensor and sensor cable for 
the bin that is displaying the message 
to make sure the sensor is seated 
correctly in the side of the tray and the 
cable is connected to the sensor and 
the control board. Check the flag for 
binding and proper operation. If 
correct, replace the Bin X sensor. If 
this does not fix the problem, replace 
the control board. 

Note: This sensor is in a normally 
open position with the flag out of the 
sensor slot. 



Bin X is full - No message that Bin X is full displays 





FRU 


Action 


1 


Bin X Sensor 


Check the sensor flag for binds, 




Bin X Sensor Cable 


broken or missing parts. If correct, 




Bin X Sensor Flag 


check the bin sensor for correct 




Bin X Sensor Flag 


installation in the side of the tray. If the 




Control Board 


bin sensor is installed correctly, check 
the sensor cable for correct installation 
to the sensor and control board. If 
correct, replace the Bin X sensor. If 
this does not fix the problem, replace 
the control board. 



Ready - Bin X Full displays and paper feeds into Bin X 





FRU 


Action 


1 


Bin X Sensor 

Bin X Sensor Control Board 


Check the sensor flag for binds. Make 
sure the sensor flag is not in an up 
position. If the sensor flag is operating 
correctly, replace the bin X sensor. If 
this does not fix the problem, replace 
the control board. 



2-86 Service Manual 



4069-XXX 

Paper does not feed into the bin selected. 271 Paper Jam - Check 
Bin 1 displays 





FRU 


Action 


1 


Deflector 
Deflector Spring 
Deflector Cover 
Deflector Cover Spring 
Shaft assemblies 


Check all the bin parts for signs of 
missing or loose springs, binds in the 
deflector or deflector cover, broken or 
binding shaft assemblies or broken 
gear teeth. If incorrect, repair as 
necessary. 


2 


Bin X Solenoid Assembly 
Control Board 


Check the solenoid for any binds. 
Make sure the solenoid is contacting 
the latch correctly. If incorrect, repair 
as necessary. If the solenoid appears 
to be operating mechanically, check 
the resistance of the solenoid. It 
measures between 30 and 50 ohms. If 
incorrect, replace the failing solenoid 
assembly. If correct, replace the 
control board. 


3 


Mechanical Linkage 
Motor Assembly 


If the DC motor is functioning properly, 
check the gears, clutch and other 
linkage parts for correct operation and 
any signs of wear, broken gear teeth 
or damaged parts. If incorrect, replace 
the mechanical linkage assembly/DC 
motor assembly. 



Diagnostic Information 2-87 



4069-XXX 

990 Service Error displays 





FRU 


Action 


1 


Mechanical Linkage 
DC Motor Assembly 


Check the DC motor cable connector 
to be sure it is correctly installed at J2 
on the control board. If correct, 
disconnect J2 from the control board 
and check the resistance of the motor 
on the cable connector. J2-1 to J2-2 
measures between 115 and 135 
ohms. Also check J2-1 and J2-4 to the 
motor case for shorts. If either the 
resistance is incorrect or a short if 
found, replace the mechanical linkage/ 
DC motor assembly. 

Note: If the DC motor is shorted, it 
may also be necessary to replace the 
control board. 


2 


Control Board 


Disconnect the motor cable J2 from 
the control board and check the 
voltages at J2 on the board. 

Note: Use caution not to short 
adjacent pins on the connector as 
damage to the board could result. 

J2-1 (motor idle) +24V dc 
J2-2 (Motor Idle) +24V dc 
J2-5 (motor idle) +5V dc 
J2-6 (motor idle) +5V dc 

If any of the voltages are incorrect, 
replace the control board. If correct, 
replace the mechanical linkage/ DC 
motor assembly. 



2-88 Service Manual 



4069-XXX 

Paper Feed Service Check 

If you have a 936 Transport Motor Error go to the "Main Drive Service 
Check" on page 2-69. 





FRU 


Action 


1 


Alignment Assembly 


Check to ensure the alignment 
assembly is correctly attached to the 
left side frame and the mounting 
screws are tight. Check the 
alignment assembly for any signs of 
worn rollers, contaminated rollers or 
binds. Replace the alignment 
assembly if any problem is found. 


2 


Inner Deflector 


Check the inner paper deflector for 
correct installation. If the deflector is 
bowed or not fitting correctly, replace 
the deflector. 



Autocompensator fails to feed paper. Failures occur randomly 
throughout the stack of paper. 





FRU 


Action 


1 


Pass Through Sensor 


Check the pass through sensor for 
correct installation and operation. 


2 


Autocompensator 
Assembly 


The autocompensator pick roll shaft 
assembly is not providing enough 
torque if the pick rollers are not 
picking the paper correctly. Replace 
the autocompensator assembly. 


3 


Wear Strips in Tray X 
problem is found. 


Check the wear strips for excessive 
wear, scratches or rough spots. 
Replace the wear strips if a problem 
is found. 



Diagnostic Information 2-89 



4069-XXX 

Paper feed failures occur only near the top of the stack of paper. 

The most common cause of this problem is paper curl. Remove the 
paper from tray x and check for the natural curvature in the paper. 
Reinstall the paper in the correct manner. If the problem persists, it 
may be necessary to reduce the stack height. Replace both pick 
rolls if the paper appears to be flat in the tray but there is still a 
problem. 

Failures occur mainly near the bottom of the stack of paper. 

The autocompensator pick arm may not be coming down far enough 
to allow the pick rolls to properly contact the paper. Also the 
autocompensator motor may be failing. If this problems continues, 
replace the autocompensator assembly. 

Double Feeding Paper 

Note: If double feeding paper occurs mostly from the bottom of the 
stack, check for missing or damaged restraint pads in the tray. 





FRU 


Action 


1 


Paper 


Paper is usually the primary cause of 
a double feeding paper problem. 
Flex the paper before placing the 
paper in the tray. Edge-welded paper 
is the most common cause of double 
feeding. Loading the paper in the 
tray in different locations and 
directions and using rough paper 
and short grain paper also causes 
double feeding. 


2 


Autocompensator 


Make sure the counterbalance 
spring is not missing, loose or 
broken at the top of the 
autocompensator arm assembly. If 
you find a problem, replace the 
autocompensator assembly. 



2-90 Service Manual 



4069-XXX 
Multipurpose Tray 

Paper fails to feed from the multipurpose tray. 

The pick roll should make one complete revolution and stop with the 
flat side down. If the pick roll turns but does not pick paper, check the 
roll for signs of wear, oil or grease on the surface of the pick roll or 
slick spots. If you find a problem, replace the pick roll assembly. 
Check to ensure the media that is being fed through the 
multipurpose tray assembly meets recommended paper 
specifications. 

Parallel Port Service Check 

Run the "Parallel Wrap Test" on page 3-1 1 . 

Note: The Parallel Wrap Test is designed to check the parallel port 
hardware by using a wrap plug (P/N 1319128) and invoking the 
Parallel Diagnostic Test. This test helps isolate the printer from the 
parallel cable and host. The test provides failure information on the 
display for approximately three seconds. If the test indicates that a 
problem is detected, replace the controller board. 



Diagnostic Information 2-91 



4069-XXX 

Printhead Service Check 

The printhead assembly does not contain any service replaceable 
parts or components. If service error code 930 displays, the wrong 
printhead is installed in the printer. 

Note: A 201 paper jam may also indicate a failing printhead. The 
paper may have jammed prior to or at the input sensor. Print the 
error log and see if 201 or 931 errors are logged. 





Service Error Code 


Explanation 


1 


Error Code 931 
No first HYSNC Signal 
Error Code 932 
Lost HYSNC 


These errors usually indicate a 
failure in the HYSNC signal to the 
printhead. Check the continuity of 
the cables connected to J3 and J8 
on the engine board. If incorrect, 
replace the defective cable. The 
voltage at J8-4 measures 
approximately +5 V dc. If incorrect, 
replace the engine board. The 
voltage at J3-7 measures 
approximately +24 V dc. If incorrect, 
replace the engine board. If correct, 
replace the printhead assembly. 


2 


Error Code 934 
Mirror Motor Lost Lock 
Error Code 935 
Mirror Motor unable to 
reach operating speed 


These error codes indicate a 
problem with the mirror motor circuit 
in the printhead assembly or the 
mirror motor cable to the engine 
board cable or engine board 
assembly. Check the continuity of 
the mirror motor cable connected to 
J3 on the engine board. If incorrect, 
replace the cable. The voltage at 
J3-7 measures approximately 
+24 V dc. If incorrect, replace the 
engine board. If correct, replace the 
FRUs in the following order: 

engine board 

printhead assembly 



2-92 Service Manual 



4069-XXX 

Print Quality Service Check 

Service Tip: Before troubleshooting any print quality problems do the 
following: 

• Install another print cartridge if available before proceeding with 
the service checks. 

• Use Tray 1 to test for print quality of the base printer. 

• Replace the charge roll if it is damaged or contaminated. 

• Replace the transfer roll if it is damaged or contaminated. 

• Make sure the fuser assembly is installed correctly. 

• Verify proper paper type, texture and weight settings for the 
media being used. 

• Test the printer using plain paper (20lb). 

Select the following menu settings as indicated. Be sure and note 
the original settings so you can return the printer to the original 
customer printer setup. 

• Print Resolution: Set to 300 dpi (print quality problems should 
be checked at different resolution settings). 

• Print Darkness: Set to NORMAL. 

• Toner Saver: Set to OFF. 

• POET: Set to OFF. 

• Fuser Temperature: Set to NORMAL. 

• Test the printer using plain paper (20 lb) 

An incorrect printer driver for the installed software can cause 
problems. Incorrect characters could print and the copy may not fit 
the page correctly. 

Measure all voltages from the connector to printer ground. All 
voltages measured during the print cycle are measured with the 
controller board removed while running the print test. 

Note: Belt Fuser (31 v/31 e) - If treeing is a problem on the printer, 
replace the belt fuser assembly. 



Diagnostic Information 2-93 



4069-XXX 

Print Quality - All Black Page 

Service Tip: An all black page is generally caused by a problem in 
the high voltage system or an incorrect high voltage in the printing 
process resulting in toner development on the entire photoconductor 
drum. 





FRU 


Action 


1 


High Voltage Contacts 


Check the high voltage contacts on 
the right side frame to ensure they fit 
securely and are not pitted, 
contaminated or damaged. If 
incorrect, replace the contact with 
one from the HV contact kit. 

Screws are included to attach the 
contacts to the right side frame in the 
HV contact kit. 


3 


Charge Roll Conductive 
Bushing 


Check to make sure the charge roll 
bushing is correctly installed in the 
right charge roll arm. 


2 


HVPS 


Check the voltages on J1 0-1 thru 
J10-8. If incorrect, replace the 
engine board. 


3 


HVPS Cable 
(Part of Front 
Harness Cable) 

Engine Board 


Check the continuity of the HVPS 
cable. If incorrect, replace the cable 
assembly. If correct, replace the 
engine board. 



Print Quality - Blank Page 





FRU 


Action 


1 


Print Cartridge 


Check the print cartridge for any 
signs of damage, especially the PC 
drum contact on the cartridge. 



2-94 Service Manual 



4069-XXX 





FRU 


Action 


2 


High Voltage Contact 


Check the PC drum contact on the 
right side frame for damage, PC 
drum contact wear or contamination. 
If the contact is bent or damaged, 
replace the contact. 

Note: Inspect the HVPS PC drum 
contact on the board for any signs of 
damage or contamination. 


3 


HVPS 


Check the fuse on the HVPS. If 
open, replace the HVPS. Check the 
voltages at J1 on the engine board. 
Measure the following voltages from 
connector J10 to printer ground: 

Printer Idle 

J10-5 measures +24 V dc 

Printer Printing 

J10-5 measures +24 V dc 

In the voltages at J10-5 are 
incorrect, replace the engine board. 


4 


Front Cable Harness 
HVPS Section 


Check the front cable harness at J10 
on the engine board and at CN1 on 
the HVPS to make sure the harness 
is connected properly. If connected 
properly, check the continuity of the 
cable harness. If there is no 
continuity, replace the front cable 
harness. 


5 


Printhead Assembly 


Generally a 93x service error is 
posted if the printhead assembly 
fails and the printer does not give a 
blank copy symptom. 

The printhead used in the printer 
does not have a mechanical shutter 
as previous laser printers. The 
printer is interlocked through the 
front top cover interlock switch. 



Diagnostic Information 2-95 



4069-XXX 

Print Quality - Random Marks 

Service Tip: The primary cause of random marks is due to loose 
material moving around inside the printer and attaching to the 
photoconductor, charge roll or transfer roll. 





Symptom 


Action 


1 


Random Marks 


Check the print cartridge for any 
signs of loose or foreign material that 
might be on the photoconductor. 
Check the transfer roll and charge 
roll for any pieces of material that are 
stuck to the rolls. 



Print Quality - Blurred or Fuzzy Print 

Blurred of fuzzy print is usually caused by a problem in the main 
drive gearbox assembly, alignment assembly, any feed roller or in 
the transfer roll bearings or transfer roll. Check the gearbox 
assembly for correct operation. Check the transfer roll for binds or a 
contaminated shaft or bearings. 

Blurred print can also be caused by incorrect feeding from one of the 
input paper sources, paper trays, duplex or envelope feeder. 

Check the high voltage contacts to ensure they are not bent, 
corroded or damaged. Replace as necessary. 



2-96 Service Manual 



4069-XXX 

Print Quality - Evenly spaced horizontal lines or marks 





FRU 


Action 


1 


Lines spaced 3.19 mm 
(.126 inch) apart 


This can be caused by the motor 
pinion gear on the main drive motor. 
Replace the main drive motor. 


2 


Lines spaced 22.32 mm 
(.882 inch) apart 

Lines spaced 28.7 mm 
(1.130 inch) apart 

Lines spaced 47.83 mm 
(1.883 inch) apart 

Lines spaced 63.77 mm 
(2.511 inch) apart 


This can be caused by a defective 
gear in the main drive gearbox 
assembly. Replace the main drive 
gearbox assembly. 


3 


Lines spaced 38.26 mm 
(1.506 inch) apart 


This can be caused by defective 
gear(s) in the main drive gearbox. 
Replace the FRUs in the following 
order: 

main drive gearbox 

reference edge 


4 


Lines spaced 44.64 mm 
(1.757 inch) apart 


Replace the FRUs in the following 
order: 

developer drive assembly 

main drive gearbox assembly 


5 


Lines spaced 47.19 mm 
(1.858 inch) apart 


Replace the FRUs in the following 
order: 

toner cartridge 

charge roll 

developer drive assembly 


6 


Lines spaced 49.16 mm 
(1.935 inch) apart 


Replace the toner cartridge. 



Diagnostic Information 2-97 



4069-XXX 





FRU 


Action 


7 


Lines spaced 49.74 mm 
(1 .958 inch) apart 


Replace the FRUs in the following 
order: 

redrive assembly 

fuser assembly 


8 


Lines spaced 51 .02 mm 
(2.009 inch) apart 


Replace the transfer roll. 


9 


Lines spaced 52.23 mm 
(2.056 inch) apart 


Replace the redrive assembly. 


10 


Lines spaced 76.53 mm 
(3.013 inch) apart 


Replace the FRUs in the following 
order: 

alignment assembly 

main drive gearbox assembly 


11 


Lines spaced 95.66 mm 
(3.766 inch) apart 


Replace the FRUs in the following 
order: 

toner cartridge 

main drive gearbox assembly 


12 


Lines spaced 99.49 mm 
(3.917 inch) apart 


Replace the redrive assembly. 


13 


Lines spaced 1 14.79 mm 
(4.519 inch) apart 


Replace the alignment assembly. 



Print Quality - Background 

Service Tip: Some background problems can be caused by rough 
papers, non-Lexmark toner cartridges or if the media texture is set to 
the rough setting. 

Some slick or coated papers may also cause background. Some 
problems occur with printers that run a large amount of graphics in a 
humid environment. The customer may try to improve the print 
quality by increasing the transfer setting. 

Check the charge roll to make sure it is not at the end of life. 



2-98 Service Manual 



4069-XXX 





FRU 


Action 


1 


Erase Lamp/Lens 
Assembly (models 010/ 
21 2/41 4/61 6/31 v/01n/21n/ 
31e/41n/61n) 


Check the erase lamp lens for any 
signs of toner, paper dust or other 
types of contamination. Clean the 
lens with a soft dry cloth if 
necessary. If unable to clean the 
contamination off the lens, replace 
the lens and lamp assembly. Check 
the erase lamp assembly. Use the 
same procedure as outlined in the 
"Erase Lamp Service Check (010/ 
21 2/41 4/61 6/31 v/01 n/21 n/31 e/41 n/ 
61 n)" on page 2-45. 


2 


Printhead 


The printhead on the Optra T 
printers cannot be cleaned. Try 
another printhead if all other 
attempts fail to correct a background 
problem. 


3 


Transfer Roll Assembly 


Check the high voltage contact from 
the HVPS to the transfer roll. Check 
the transfer arm assembly right side 
bearing for any signs of 
contamination, pitting or a loose 
cable to the bearing. If any problems 
are found, replace the defective part. 
Check the transfer roll shaft for any 
signs of contamination, wear or 
pitting on the ends of the shaft that 
go into the bearings. If a problem is 
found, clean the ends of the shaft or 
replace the transfer roll assembly. 


4 


High Voltage Contacts 


Check the high voltage contacts on 
the right side frame to ensure they 
are clean and not bent, deformed, or 
pitted. If incorrect, replace the 
contact. 



Diagnostic Information 2-99 



4069-XXX 



FRU 



Action 



Engine Board HVPS 
Connector 



Check the following voltages at J1 
on the engine board. Measure the 
voltages from J1 to printer ground. 

Printer Idle 

J10-1 approximately V dc 
J1 0-2 approximately 4 V dc 
J1 0-4 approximately V dc 

Printer Printing 

J10-1 varies V dc to +5 V dc 
J1 0-2 varies V dc to +4 V dc 
J 10-4 varies Vdcto +1.9 V dc 

If J10-1 voltage is incorrect, check 
the continuity of the front harness 
cable (J10-1 line). If there is no 
continuity, replace the harness 
cable. If there is continuity, replace 
the HVPS. If this does not correct the 
problem, replace the engine board. 

If J1 0-2 voltage is incorrect or if the 
voltage remains at V dc, check the 
continuity of the front harness cable 
(J10-2 line). If there is no continuity, 
replace the harness cable. If there is 
continuity, replace the HVPS. If this 
does not correct the problem, 
replace the engine board. 

If J1 0-4 voltage is incorrect, check 
the front harness cable (J10-3 line). 
If there is not continuity, replace the 
harness cable. If correct, replace the 
engine board, if this does not correct 
the problem, replace the HVPS. 



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4069-XXX 

Print Quality - Banding 

Service Tip: Banding is difficult to detect except on a page with a 
uniform gray or a large amount of graphics printed on the page. 
Banding is primarily due to a variation in the speed of the paper as it 
feeds thru the printer, especially in the development and transfer 
process. Inspect the alignment assembly, main drive assembly and 
all other paper feed components for signs of wear, dirt, binds, or 
damage, especially the drive gears. Banding appears as light or dark 
horizontal lines on a uniformly gray page. 

Banding can also be caused by a defective charge roll brush contact 
or HVPS. Check the charge roll contact for any signs of damage and 
for proper connection to the HVPS and print cartridge. 

Print Quality - Black bands on outer edges of the page 

This print quality problem appears as vertical black bands on one or 
both sides of the copy and can be wide, narrow, light or dark. 





FRU 


Action 


1 


Charge Roll 
Counterbalance Springs 


If the problem is just on one side of 
the page, check the charge roll 
counterbalance spring on that side. 
You can check to see if enough force 
is being applied to the charge roll by 
applying a slight downward pressure 
with your finger to the charge roll link 
arm that the spring is attached to 
while you run a print test sample. 
See if the problem changes or goes 
away. If this fixes or changes the 
problem, then check the springs and 
charge roll link arm assemblies for 
binds or defective parts. Replace as 
necessary. 



Diagnostic Information 2-101 



4069-XXX 





FRU 


Action 


2 


Charge Roll Assembly 
Charge Roll Link Arm 


Check the charge roll for any signs 
of toner buildup or other 
contamination on the outer edges 
that correspond to the bands on the 
page. Check the charge links and 
arms for proper operation, binds or 
incorrectly mounted counterbalance 
springs. Repair or replace as 
necessary. 


3 


HVPS 


Check the following voltages at 
J10-8 on the engine board: 

Printer Idle 

J10-8 measures V dc 

Printer Printing Test Page 

J10-8 voltage changes from V dc 

to +4 V dc 

If the voltage does not vary check 
the continuity of line J10-8 in the 
front cable harness. If there is no 
continuity, replace the cable 
harness. If there is continuity, 
replace the HVPS. If this does not 
correct the problem, replace the 
engine board. 

Turn the printer Off and check the 
resistance between J10-7 and 
printer ground. The resistance 
measures approximately ohms. If 
incorrect, make sure the engine 
board is mounted correctly and 
securely grounded. If correct, 
replace the engine board. 



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4069-XXX 

Print Quality - Residual Image 

Service Tip: Install a new print cartridge if available before doing this 
service check. Residual image can be caused by the 
photoconductor, cleaning blade and other parts inside the print 
cartridge. 





FRU 


Action 


1 


Erase Lamp Assembly 
(models 010/212/414/616/ 
31v//01n/21n/31e/41n/61n) 


Check the erase lamp lens assembly 
for any signs of paper dust, toner 
buildup or any other contamination. 
Clean with a soft cloth or replace the 
lens and lamp assembly which are 
provided together in a kit. If the lens 
is clean then check the erase lamp 
assembly for failed erase lamps. If 
defective, replace the erase lamp 
assembly. 


2 


Hot Roll Fuser Assembly 


Check the fuser assembly for signs 
of toner contamination. The hot roll 
especially might cause toner to be 
retained and deposited on the page. 


3 


BeltFuser(31v/31e) 


Toner buildup on the belt can cause 
toner to be carried out on the 
backside of the media. If any toner 
buildup is present on the belt, 
replace the belt fuser assembly. 



Diagnostic Information 2-103 



4069-XXX 

Print Quality - Light Print 

Service Tip: Check the toner saver and print darkness settings first if 
the print is light. 





FRU 


Action 


1 


Transfer Roll 


Check the right end of the transfer 
roll shaft for signs of wear or 
contamination. If incorrect, replace 
the transfer roll. 


2 


Right Side Transfer Roll 
Arm Assembly 


Check the right side transfer roll arm 
assembly bearing for any signs of 
wear or contamination. Also check to 
ensure the transfer cable is firmly 
attached to the bearing. If incorrect, 
replace the right side transfer arm 
assembly. Check the connection of 
the transfer roll assembly cable to 
the transformer on the HVPS board. 
Check the continuity of the cable 
from the bearing to the spade 
terminal on the cable. If incorrect, 
replace the right side transfer arm 
assembly. If correct, replace the 
HVPS. 



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4069-XXX 

Print Quality - Toner on backside of printed page 

Service Tip: This is generally caused by loose toner in the machine 
in the paper path being carried through the printer on the backside of 
the paper. 





FRU 


Action 


1 


Hot Roll Fuser Assembly 


Toner is being carried out on the 
backside of the media. This problem 
is generally caused by a toner 
buildup on the fuser hotroll or backup 
roll. Check the fuser hotroll and 
backup roll for any noticeable 
buildup of toner. Repair as 
necessary. 


2 


Belt Fuser(31v/31e) 


Toner buildup on the belt can cause 
toner to be carried out on the 
backside of the media. If any toner 
buildup is present on the belt, 
replace the belt fuser assembly. 


3 


Transfer Roll Transfer Plate 
Assembly 


Check the transfer roll for any signs 
of toner buildup or loose toner 
around the area of the transfer plate 
assembly. Clean the area and run 
another copy. If the problem 
continues, replace the FRUs in the 
following order: 

HVPS 

engine board 



Diagnostic Information 2-105 



4069-XXX 

Smart Cartridge Service Check 

Note: If you are unable to clear a "32-Unsupported Cartridge" User 
Error Message, make sure an Optra T print cartridge is correctly 
installed in the printer. The cartridge is easily identified by the smart 
chip located on the top right side of the cartridge. Install another 
print cartridge before attempting to troubleshoot the printer. Check to 
make sure the smart cable is properly connected to J21 on the 
engine board. Check the print cartridge for any signs of damage or 
improper installation of the smart chip. Also check to make sure 
there is proper contact between the smart chip and the smart 
cartridge contacts. 

Service Tip: An intermittent "32-Unsupported Cartridge" User Error 
Message can be caused by poor contact between the smart 
cartridge contacts in the upper front cover and the smart chip. Also 
check for proper seating of the smart cartridge cable to the engine 
board. 





FRU 


Action 


1 


Smart Cartridge Contact 
Smart Cartridge Ground 
Contact 


Check both contacts to make sure 
they are properly installed and the 
two contacts are not touching each 
other. Check both contacts for any 
signs of being bent, worn or broken. 
If incorrect replace both contacts. 


2 


Smart Cartridge Cover 


Check to make sure that the smart 
cartridge cover is properly snapped 
into place and is not damaged or 
broken. Replace as necessary. 


3 


Smart Cartridge Plunger 


Check the plunger for correct 
installation and any signs of being 
damaged or broken. Correct any 
problem found or replace the plunger 
as necessary. 



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4069-XXX 





FRU 


Action 


4 


Smart Cartridge Cable 
Engine Board 


Check the voltage on the smart 
cartridge contact. The voltage 
measures approximately +5 V dc 
when not writing data to the engine 
board. If data is being written, the 
voltage measures approximately 
+1 2 V dc. If incorrect, disconnect the 
cable from J21 on the engine board 
and check the voltage on J21 -1 . The 
voltage measures approximately 
+5 V dc. If incorrect, replace the 
engine board. If correct, replace the 
smart cartridge cable. 



Serial Port Service Check 

Run the "Serial Wrap Test" on page 3-12. 

Note: The Serial Wrap Test is designed to check the serial port 
hardware by using a wrap plug (P/N 1329048) and invoking the 
Serial Post Diagnostic Test. The test helps isolate the printer from 
the serial cable and host. The test provides failure information on the 
display for approximately three seconds. If the test indicates a 
problem, replace the controller board. 

Toner Sensor Service Check 

Service Tip: Check the print darkness MENU setting before 
checking the toner sensor. 

This service check is intended to be used when a 929 Service Error 
displays. 





FRU 


Action 


1 


Developer Drive Assembly 


Incorrect operation of the developer 
drive assembly can cause the printer 
to display a 929 error code (Toner 
Sensor). Check the developer drive 
assembly for correct installation, any 
sign of worn, loose or broken parts. 



Diagnostic Information 2-107 



4069-XXX 





FRU 


Action 


2 


Front Harness Cable 


Check the toner sensor portion of 
the front harness cable to make sure 
it is properly seated into the toner 
sensor. If correct at both the sensor 
and engine board (J1 0), check the 
continuity of the cable. If incorrect, 
replace the cable. 


3 


Toner Sensor 


The toner sensor cable is part of the 
front harness and part of connector 
J10 on the engine board. Check the 
voltage at J 1 -01 1 . It reads 
approximately +5 V dc. If incorrect, 
replace the engine board. If correct, 
check the voltage at J1 0-1 2. It reads 
approximately +5 V dc with the 
controller board removed from the 
printer. If incorrect, replace the 
engine board. If correct, replace the 
toner sensor assembly. A bad 
ground connection between J10-13 
on the engine board and pin 3 on the 
toner sensor results in a 929 service 
error. 



Transfer Roll Service Check 

Service Tip: The transfer roll is 51 .02 mm (2.009 inch) diameter. Any 
print quality problems such as lines that are spaced 15.2 mm apart 
indicate you should check the transfer roll for damage, toner or 
foreign material buildup. 

Service Tip: The transfer roll assembly is part of the Maintenance Kit 
and is replaced when a '80 Scheduled Maintenance" message 
displays. Ask the customer if they have replaced the transfer roll 
recently. 

CAUTION: Make sure the printer is powered Off before making any 
checks on the transfer roll or associated parts for personal safety 
and to prevent damage to the printer. 

Note: Error Code 917 

A 91 7 transfer roll error code on all models at service level B may 
display if an incorrect level HVPS is installed in a printer that has the 



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4069-XXX 

is installed in a printer that has the erase lamp assembly installed. 
Check to make sure the correct level HVPS is installed. Go to "Printer 
Serial Label" on page 7-2 to identify the printer service level. 





FRU 


Action 


1 


Transfer Roll Assembly 


Check the transfer roll for any signs 
of toner buildup, surface damage to 
the roll, oil or other contaminants on 
the surface of the roll. Replace the 
transfer roll as necessary. 


2 


Left Transfer Arm Assembly 


Check the left transfer roll arm 
assembly to make sure it is fastened 
and locked in the down position. If 
the arm is not locked down, check to 
ensure the arm is not broken and will 
lock into the EP frame correctly. 
Check the left transfer arm assembly 
spring for proper operation. 


3 


Right Transfer Arm 
Assembly 


Check the right transfer arm 
assembly to make sure it is fastened 
and locked in the down position. If 
the arm is not locked down, check to 
make sure the arm is not broken and 
will lock into the EP frame correctly. 
Check the right transfer arm 
assembly spring for proper 
operation. For any background 
problems, check to ensure the 
contact to the HVPS board is correct 
and that there is approximately 
ohms resistance between the 
transfer roll shaft and the HVPS 
contact. If correct, go to "Print 
Quality - Background" on page 2-98. 



Diagnostic Information 2-109 



4069-XXX 





FRU 


Action 


4 


HVPS-917 Error Code 


Check the voltage at J 10-3. The 
voltage changes from +24 V dc with 
the printer idle to V dc when the 
printer runs the print test. If the 
voltage is incorrect, check the 
continuity of line J1 0-3 in the front 
cable harness to the HVPS. If there 
is no continuity, replace the cable 
harness. If there is continuity, 
replace the HVPS. If the problem 
continues, replace the engine board. 
Note: This error displays if the 
incorrect level HVPS is installed. 



2-110 Service Manual 



4069-XXX 



3. Diagnostic Aids 

This chapter explains the tests and procedures to identify printer 
failures and verify repairs have corrected the problem. 

To run the printer diagnostic tests described in this chapter, you 
must put the printer in Diagnostic Mode. 

Diagnostic Mode 

To enter the Diagnostic Mode: 

1 . Turn the printer off. 

2. Press and hold the Go and Return buttons. 

3. Turn the printer on. 

4. Release the buttons when "Performing Self Test" displays on 
the operator panel. 

The tests display on the operator panel in the order shown: 

Print Registration 

Print Tests 

Hardware Tests 

Duplex Tests (If installed) 

Input Tray Tests 

Output Bin Tests 

Five Bin Mailbox Test 

Base Sensor Test 

Printer Setup 

Error Log 

EP Factory Defaults 

Exiting the Diagnostics Mode 

Select Exit Diagnostics to exit the Diagnostics Mode and return to 
normal mode. 



Diagnostic Aids 3-1 



4069-XXX 



Device Tests 

Quick Disk Test 

This test performs a non-destructive read/write on one block per 
track on the disk. The test reads one block on each track, saves the 
data, and proceeds to write and read four test patterns to the bytes 
in the block. If the block is good, the saved data is written back to the 
disk. 

To run the Quick Disk Test: 

1 . Select the Quick Disk Test from the Device Tests menu. 

- The power indicator blinks while the test is in progress. 

- "Quick Disk Test/Test Passed" message displays if the test 
passes and the power indicator turns on solid. 

- "Quick Disk Test/Test Failed" message displays if the test 
failed and the power indicator turns on solid. 

2. Press Go, Return, or Stop to return to the Device Tests menu. 

Disk Test/Clean 

WARNING: This test destroys all data on the disk and should not be 
attempted on a good disk. Also note that this test may run 
approximately 1 1/2 hours depending on the disk size. 

To run the Disk Test/Clean Test: 

1 . Select Disk Test/Clean from the Device Tests menu. 

- "Files will be lost/Go or Stop?" message displays to warn the 
user that all contents on the disk will be lost. 

2. To exit the test immediately and return to the Device Tests 
menu, press Return/Stop. To continue with the test, press Go. 

- If go is selected, "Disk Test/Clean/BAD:000000 00%" 
message displays. The screen updates periodically 
indicating the percentage of test completed and the number 
of bad blocks found. 

3. The power indicator blinks during the test. The test can be 
canceled anytime during the test by pressing Return/Stop. 

- Once the test is complete, the power indicator turns on solid 
and a message displays. 



3-2 Service Manual 



4069-XXX 

- "xxxx Bad Blocks/yyyyyy Usable" message displays if fewer 
than 2000 bad blocks are detected, xxxx indicates the 
number of bad blocks and yyyyyy indicates the number of 
usable blocks. 

- "xxxx Bad Blocks/Replace Disk" message displays if more 
than 2000 bad blocks are detected. The disk cannot be 
recovered because too many bad blocks exist on the disk. 

4. Press Go or Return/Stop to return to the Device Tests menu. 

Flash Test 

This test causes the file system to write and read data on the flash to 
test the flash. 

WARNING: This test destroys all data on the flash because the 
flash is reformatted at the end of the test. 

To run the Flash Test: 

1 . Select Flash Test from the Device Tests menu. 

- The power indicator blinks while the test is running. 

- "Flash Test/Test Passed" message displays if the test passes 
and the power indicator turns on solid. 

- "Flash Test/Test Failed" message displays if the test fails and 
the power indicator turns on solid. 

2. Press Go or Return/Stop to return to the Device Tests menu. 

Disabling Download Emulations 

Error Code 964: Download Emulation CRC Failure. Checksum 
failure detected in the emulation header or emulation file. 

Error Code 965: Download Emulation Outdated. Time stamps 
indicate the download emulation and RIP code are incompatible. 

To help resolve Download Emulation problems the following steps 
are necessary to instruct the printer to POR without activating any 
download emulations. 

To Disable the Download Emulation: 

1 . Turn the printer off. 

2. Press and hold the Go and Menu buttons. 



Diagnostic Aids 3-3 



4069-XXX 

3. Turn the printer On and release the buttons once "Performing 
Self Test" displays. 

- Once the printer is idle, the emulation can be downloaded 
again. 

4. Program the download emulation into the code overlay SIMM 
again. 

5. If these steps do not resolve the problem, replace the code 
overlay SIMM and download the emulation again. 



Duplex Tests 

Duplex Quick Test 

This test is used to verify that the Duplex Option Top Margin is set 
correctly. This test prints a duplexed version of the Quick Test Page 
that can be used to adjust the Top Margin for the backside of the 
duplexed page. You can run one duplexed page (Single) or continue 
printing duplexed pages (Continues) until Return/Stop is pressed. 

The paper you choose to print the page on should be either Letter or 
A4. 

To run the Duplex Quick Test: 

1 . Select Duplex Quick Test from the menu. 

2. Select Single or Continuous. 

- The single Duplex Quick test cannot be canceled. 

The printer attempts to print the Quick Test Page from the default 
paper source. If the default paper source only supports envelopes, 
then the page is printed from Tray 1 . 

Check the Quick Test Page for the correct offset between the 
placement of the first scan line on the front and back side of a 
duplexed sheet. 

If adjustment is necessary the Top Margin Offset must be adjusted 
first. The range of the adjustment is -25 to +25. The Duplex Top 
Margin Offset range is -20 to +20. 

Adjustment of this setting lets you shift up or down the position of the 
Top Margin. Changing this parameter by 1 unit moves the margin 

3-4 Service Manual 



4069-XXX 

1/100 inch. A positive offset moves the text down the page and 
widens the top margin while a negative offset moves the text up the 
page and narrows the top margin. 

3. Press Return/Stop to exit the test. 

Check the Top Margin Offset of the base printer. 

Duplex Sensor Test 

This test is used to determine whether or not the Duplex sensors 
and switches are working correctly. 

Select Sensor Test from the Duplex Tests menu. 

Manually actuate each of the duplex sensors. When the sensor/ 
switch is closed, CL (closed) displays, when the sensor/switch is 
open, OP (Open) displays. 

Duplex input sensor 
Duplex exit sensor 

Press Return/Stop to exit the test. 

Duplex Motor Test 

This test lets you test the duplex unit's paper feed drive system, and 
verify that the power and velocity values are acceptable. 

To run the Duplex Motor Test: 

1 . Select Motor Test from the Duplex Tests menu. The duplex 
motor test continues to run until the printer is powered off. 

- The power indicator blinks while the test is running. 

- The duplexer runs the motor at a high speed and then a low 
speed and takes an average of the power required for each 
speed. 

- After all the information is computed, the motor turns off. 



Diagnostic Aids 3-5 



4069-XXX 

The following appears on the printer display: 

DUPLEX MOTOR AA 
BBCCDDEEFF 

To pass the test the following results must display: 

AA = 00 

BB = in the range of 20 through 3F inclusively (hex) 
CC = in the range of 3A through 5D inclusively (hex) 
DD = in the range of 1 1 through 1 F inclusively (hex) 
Ignore bytes EE and FF 

If the test fails, remove the drive belt from the duplex D.C. motor and 
run the motor test again. For the duplex D.C. motor to pass the test 
the following results must display: 

AA = 00 

BB = in the range of 29 through 3E inclusively (hex) 
CC = in the range of 35 through 51 inclusively (hex) 
DD = in the range of 0C through 13 inclusively (hex) 

For the duplex drive system to pass the test the following results 
must display: 

AA = 00 

BB = in the range of 29 through 3F inclusively (hex) 
CC = in the range of 3A through 5D inclusively (hex) 
DD = in the range of 1 1 through 1 F inclusively (hex) 

2. Press Return/Stop to exit the test. 



3-6 Service Manual 



4069-XXX 

Duplex Feed 1 Test 

This test feeds a blank sheet of paper to the duplex paper stop 
position 1 . 

To run the Duplex Feed 1 Test: 

1 . Select Duplex Feed 1 from the Duplex Test menu. 

- The power indicator blinks while the paper is feeding. 

- "Duplex Feed 1 /Feeding" message displays while the paper 
is feeding through the printer. 

- "Duplex Feed 1 /Clear Paper" message displays when the 
paper reaches paper stop position 1 and the power indicator 
turns on solid. 

Duplex Feed 2 Test 

This test feeds a blank sheet of paper to the duplex paper stop 
position 2. 

To run the Duplex Feed 2 Test: 

1 . Select Duplex Feed 2 from the Duplex Test menu. 

- The power indicator blinks while the paper is feeding. 

- "Duplex Feed 2/Feeding" message displays while the paper 
is feeding through the printer. 

- "Duplex Feed 2/Clear Paper" message displays when the 
paper reaches the duplex paper stop position 2 and the 
power indicator turns on solid. 



Diagnostic Aids 3-7 



4069-XXX 



Error Log 

Viewing the Error Log 

The error log is helpful to the servicer by providing a history of 
printer errors. The error log contains the 12 most recent errors that 
have occurred on the printer. The most recent error displays in 
position 1 and the oldest error displays in position 12 (if 12 errors 
have occurred). If an error occurs after the log is full, the oldest error 
is discarded. Identical errors in consecutive positions in the log are 
entered. All 2xx and 9xx error messages are stored in the error log. 

To view the Error Log: 

1 . Select Display Log from the Error Log menu. 

- The Error log displays on three screens as only four entries 
display at a time. 

2. To move to the next screen press Menu> to move forward or 
<Menu to move backward. 

3. Press Return/Stop to exit the Error Log. 

Clearing the Error Log 

To clear the Error Log: 

1 . Select Clear Log from the Error Log menu. 

2. Select "YES" to clear the Error Log or "NO" to exit the Clear Log 
menu. 

- If "YES" is selected, the Empty Error Log displays on the 
screen. 

3. Press Return/Stop to exit the Clear Log menu. 



3-8 Service Manual 



4069-XXX 



Hardware Tests 

The following Hardware Tests can be selected from this menu: 

LCD Test 
Button Test 
DRAM Memory Test 
ROM Memory Test 
Parallel Wrap (if available) 
Serial Wrap (if available) 
Serial 1 Wrap (if available) 
Serial 3 Wrap (if available) 

LCD Test 

To run the LCD Test: 

1 . Select LCD Test from the Diagnostic menu. 

- The LCD test continually executes the LCD display test. 

2. Press Return/Stop to cancel the test. 

Button Test 

To run the Button Test: 

1 . Select Button Test from the Diagnostic menu. 

- With no buttons pressed, several OP (Open) appear on the 
display. 

2. Press each button one at a time and a CL (Closed) displays in 
place of an OP. The proper operation of each button can be 
checked. 

3. Press Return/Stop to cancel the test. 



Diagnostic Aids 3-9 



4069-XXX 

SDRAM Memory Test 

The purpose of this test is to check the validity of SDRAM, both 
standard and optional. The test writes patterns of data to SDRAM to 
verify that each bit in memory can be set and read correctly. 

To run the SDRAM Memory Test: 

1 . Select SDRAM Memory Test from the menu. 

- The power indicator blinks indicating the test is in progress. 

2. Press Return/Stop to exit the test. 

P:###### represents the number of times the memory test has 
passed and finished successfully. Initially 000000 displays with the 
maximum pass count being 999,999. 

F:##### represents the of time the memory test has failed and 
finished with errors. Initially 00000 displays with the maximum fail 
count being 99,999. 

Once the maximum pass count or fail count is reached, the test is 
stopped, the power indicator is turned on solid, and the final results 
display. If the test fails, the message SDRAM Error, displays for 
approximately three seconds and the failure count increases by 1 . 

ROM Memory Test 

The ROM Memory Test is used to check the validity of the controller 
board code and fonts. 

To run the ROM Memory Test: 

1 . Select ROM Memory Test from the menu. P and F represent the 
same numbers for DRAM. 

- The power indicator blinks indicating the test is in process. 
The test runs continuously. 

2. Press Return/Stop to exit the test. 



3-10 Service Manual 



4069-XXX 

Each time the test finishes, the screen updates with the result. If the 
test passes, the Pass Count increases by 1 , however if the test fails, 
one of the following messages displays for approximately three 
seconds: 

ROM Checksum Error 
ROM Burst Read Error 

Once the maximum pass count or fail count is reached, the test 
stops with the power indicator on solid. The final results display on 
the screen. 

Parallel Wrap Test 

This test is used with a wrap plug to check operation of the parallel 
port hardware. Each parallel signal is tested. 

To run the Parallel Wrap Test: 

1 . Disconnect the parallel interface cable and install the wrap plug 
(P/N 1319128). 

2. Select the Parallel Wrap Test from the menu. 

- The power indicator blinks indicating the test is in progress. 
The test runs continuously until canceled. 

Each time the test finishes, the screen updates. If the test passes, 
the Pass Count increases by 1 , however if the test fails, one of the 
following messages displays for approximately three seconds: 

Sync Busy Error 

Byte Interrupt Request Error 

Strobe Interrupt Request Error 

Init Fail Error 

Init Busy Error 

Init Rise Error 

Host Busy Error 

RAM Data FF Error 

RAM Data AA Error 

RAM Data 00 Error 

RAM Data 55 Error 

DMA Count Error 



Diagnostic Aids 3-11 



4069-XXX 

DMA Address Error 
DMA Interrupt Error 
DMA Memory Error 
DMA Background Error 
Clear Init Rise Error 
False Init Rise Error 
Autofeed Rising Interrupt Error 
Clear Autofeed Rise Error 
False Autofeed Rise Error 
Autofeed Falling Interrupt Error 
Clear Autofeed Fall Error 

Once the maximum count is reached the test stops. The power 
indicator goes on solid and the final results display. 

Press Return/Stop to exit the test. 
Serial Wrap Test 

This test is used to check the operation of the Serial Port Hardware 
using a wrap plug. Each signal is tested. 

To run the Serial Wrap Test: 

1 . Disconnect the serial interface cable and install the wrap plug. 

2. Select the appropriate Serial Wrap Test from the menu: Serial 
Wrap, Serial 1 Wrap, Serial 2 Wrap or Serial 3 Wrap. P and F 
represent the same numbers for DRAM. 

- The power indicator blinks indicating the test is running. 

3. This test runs continuously unless canceled by pressing Return/ 
Stop. 



3-12 Service Manual 



4069-XXX 

Each time the test finishes, the screen updates with the result. If the 
test passes, the Pass Count increases by 1 , however if the test fails, 
one of the following failure messages displays for approximately 
three seconds and the Fail Count increases by 1 : 

Receive Status Interrupt Error 

Status Error 

Receive Data Interrupt Error 

Transmit Data Interrupt Error 

Transmit Empty Error 

Threshold Error 

Receive Data Ready Error 

Break Interrupt Error 

Framing Error 

Parity Error 

Overrun Error 

Data Error 

Data 232 Error 

Data 422 Error 

FIFO Error 

DSR Error 

DSR PIO Error 

DSR Interrupt Error 

CTS Error 

CTS PIO Error 

CTS Interrupt Error 

Once the maximum count is reached the test stops. The power 
indicator goes on solid and the final results display. 

Press Return/Stop to exit the test. 



Diagnostic Aids 3-13 



4069-XXX 



Input Tray Tests 

Input Tray Feed Test 

This test lets the servicer observe the paper path as media is 
feeding through the printer. A blank sheet of paper feeds through the 
printer as the laser turns off during this test. The only way to observe 
the paper path is to open the lower front door that is used to access 
the envelope or multipurpose feeder. The paper is placed in the 
output bin. 

To run the Input Tray Feed Test: 

1 . Select Input Tray Feed Test from the menu. 

2. Select the input source from the sources displayed on the Feed 
Test menu. All installed sources are listed. 

3. Select either Single (feeds one sheet of media from the selected 
source) or Continuous (continues feeding media from the 
selected source until Return/Stop is pressed). 

4. Press Return/Stop to exit test. 

Input Tray Sensor Test 

This test is used to determine if the input tray sensors are working 
correctly. 

To run the Input Tray Sensor Test: 

1 . Select the Sensor Test from the Input Tray Test menu. 

- "Input Tray/Empty=OP/Pass=OP" message displays. 

- EM = Input Tray Empty Sensor 

- LO = Input Tray Paper Low Sensor 

- P = Input Tray Pass Thru Sensor 

2. Once this message displays, the servicer can manually actuate 
each sensor. The tray empty sensor can be actuated by hand, 
however a sheet of paper can be used to cover the pass 
through sensor. When the sensor is closed, CL displays, when 
the sensor is open, OP displays. 

3. Press Return/Stop to exit the test. 



3-14 Service Manual 



4069-XXX 

The multipurpose tray and the envelope feeder do not have a paper 
low sensor. The multipurpose tray does not have a pass through 
sensor. 

Output Bin Test - Standard Bin 

This test is used to verify if the standard bin sensor is working 
correctly. 

To run the Standard Bin Sensor Test: 

1 . Select Output Bin Tests from the Diagnostic Menu. 

2. Select Output Bin Tests - Sensor Tests. 

3. Select Sensor Tests - Standard Bin. 

- "Standard Bin/Full=CL" message displays. 

Manually actuate the bin sensor by moving the flag in and out of the 
sensor. The display indicates OP (open) when the flag is out of the 
sensor and CL (closed) when the flag is in the sensor. 

4. Press Return/Stop to exit the test. 
Output Bin Feed Test 

Note: If the "Configure Bins" printer setting is link rather than 
mailbox, the printer selects its own internal bin linking regardless of 
which output bin is selected for the feed test 

This test is to verify that media can be fed to a specific output bin. No 
information is printed on the media because the printhead is not 
turned on during this test. 

To run the Output Bin Feed Test: 

1 . Select Feed Test from the Output Bin Test menu. 

2. Select the output bin you want the paper to exit into. All output 
bins installed on the printer are shown on the feed test menu. 

3. Select either Single (one sheet of media feeds to the selected 
output bin) or Continuous (media continues feeding to the 
selected output bin) until Return/Stop is pressed. 

4. Press Return/Stop to exit the test. 



Diagnostic Aids 3-15 



4069-XXX 

Output Bin Sensor Test 

This test is used to verify if the output bin sensors are working 
correctly. 

To run the Output Bin Sensor Test: 

1 . Select Sensor Test from the Output Bin Test menu. 

- "Output Bin/Full=OP/lnput=OP" message displays. 

- Full = Output Bins Full Sensor 

- Pass = Output Bins Pass Thru Sensor 

2. Once the message displays, the servicer can manually actuate 
each of the output bin sensors. The bin full sensor can be 
actuated by hand, however a sheet of paper can be used to 
cover the bin's pass thru sensor. When the sensor is closed CL 
displays, and when the sensor is open OP displays. 

3. Press Return/Stop to exit the test. 

Output Bin X Sensor Test 

Output Expander or High Capacity Output Stacker 

To run the Output Bin X Sensor tests: 

1 . Select Output Bin tests from the menu. 

2. Select Output Bin tests - Sensor Tests. 

3. Select Sensor Tests - Output Bin X. 

4. Press Return/Stop to exit the test. 

The following is displayed: 

Output Bin X 

P=OP F=OP NF=CL 

P = Pass Thru Sensor 

F = BIN FULL Sensor (lower part of dual sensor) 

NF = Near Full Sensor (upper part of dual sensor) 

Once the message displays, you can manually actuate each of the 
output bin sensors. For all the sensors except the output level 
sensor, when the sensor is closed CL displays and when the sensor 
is open OP displays. 

3-16 Service Manual 



4069-XXX 

If the high capacity output stacker is selected then the following is 
displayed: 

HCBIN 1 

TP=OP, P=OP, F=OP, NF=OP 

IP = high capacity output stacker top position sensor 

P = high capacity output stacker passthru sensor 

F = high capacity output stacker full sensor 

NF = high capacity output stacker near full sensor 

If the 5-bin mailbox is selected the following is displayed: 

<output bin> (output bin displayed on line 1 = output bin 1, 

output bin2, output bin3, output bin4 or output bin 5 for the bin 

selector) 

P1 = 5-bin mailbox first passthru sensor 

P2 = 5-bin mailbox second passthru sensor 

L = EM, indicates 5-bin x empty 

L = NL, bin contains media but the bin is not near full on full 

L = NF, indicates bin is near full 

L = FL, indicates bin is full 

Base Sensor Test 

This test is used to determine if the sensors located inside the 
printer are working correctly. 

The following sensors can be checked: 

Toner Optical Sensor 

Input Sensor 

Output Sensor (Fuser Exit) 

Narrow Media Sensor 

Front Door Sensor (Upper Front Cover) 

To run the Base Sensor Test: 

1 . Select the Base Sensor Test. 

- The operator panel displays OP for open and CL for closed. 

2. Manually toggle the sensors by hand to verify that each sensor 
switches from open to closed. 



Diagnostic Aids 3-17 



4069-XXX 

5-Bin Mailbox Diverter Test 

Note: This test checks the operation of each mailbox output 
diverter. Also if more than one 5-bin mailbox option is installed, the 
test checks all of the diverters installed on the printer. 

When the test is selected from the diagnostic menu the following is 
displayed: 

Diverter Test Running 

This is a single test. The test terminates upon completion. 



3-18 Service Manual 



4069-XXX 



Print Registration 

The print registration range is as follows: 

Bottom Margin: -20 to +20 Each increment causes 
approximately.55 mm shift in the bottom margin. 
Top Margin: -25 to +25 
Left Margin: -25 to +25 
Right Margin: -10 to +10 

To set Print Registration: 

1 . Select Registration from the Diagnostic menu. 

2. The Top margin sign/value pair blinks. This indicates it is the 
margin value being changed. 

3. To select the margin value to be changed press Select until the 
margin value pair you want to change is blinking. 

4. To change the margin value press either Menu> or <Menu. 
When the value you want is displayed, press Select to save the 
value. 

5. To exit the Registration menu, press Return. 

To verify the margin values are correct you must print the "Quick Test 
Page" from the registration screen. Press Go to print the test page. 
While printing the Quick Test Page the "Quick Test Printing" 
message displays. Once the Quick Test Page completes printing, 
the Registration screen displays again. 

The "Quick Test Page" should be printed on letter or A4 paper. 



Diagnostic Aids 3-19 



4069-XXX 



Printer Setup 

Setting the Page Count 

This lets the servicer change the page count from the diagnostic 
menu. This is used whenever the engine board is replaced because 
this board contains the printer's NVRAM Memory where the page 
count is stored. 

To set the Page Count: 

1 . Select Page Count from the Diagnostic menu. 

- The current page count displays. 

- The leftmost digit blinks, indicating it is the first digit to be 
changed. 

2. Press either Menu> or <Menu until the value you want displays. 

3. Press Select to move to the next digit, press Menu> or <Menu 
until the value you want displays. Continue with each digit until 
you set the page count. You can skip any digit by pressing 
Select. 

4. Press Select to save the new page count in NVRAM. 

5. Press Return/Stop to exit the Diagnostic menu. 

Viewing the Permanent Page Count 

The Permanent Page Count can only be viewed and cannot be 
changed. 

To view the Permanent Page Count: 

1 . Select Permanent Page Count from the menu. 

2. Press Return/Stop to exit the Diagnostic menu. 



3-20 Service Manual 



4069-XXX 

Maintenance Page Count 

This counter is reset by the servicer after a "80 Scheduled 
Maintenance" message displays (250K copies) and a maintenance 
kit is installed. 

To view the Maintenance Page Count: 

1 . Select Maintenance Count Value from the diagnostic menu. 

2. Press Return to go to the previous menu. 

To reset the Maintenance Page Count to zero: 

1 . Select Reset Maintenance Count. Pressing Select causes the 
maintenance page counter to reset to zero. 

- Reset Maintenance Count Saved displays momentarily. 
When the reset operation is complete, the menu returns to 
the Printer Setup Reset Maintenance Count screen. 

Setting Configuration ID 

The configuration ID is used to communicate information about 
certain areas of the printer that cannot be determined using 
hardware sensors. The Configuration ID is originally set at the 
factory when the printer is manufactured, however it requires 
resetting whenever you replace the engine board and can be set on 
the operator panel. However the Configuration ID is the only 
diagnostic function displayed until a valid ID is entered. 

To set the Configuration ID: 

1 . Enter the Diagnostic Mode. 

2. Select Configuration ID from the Printer Setup menu. 

- The current ID displays on the screen. The Configuration ID 
is on a label located inside the printer. The label is attached 
to the top front cover hinge assembly and is visible when the 
top front cover is open. 

- The leftmost digit blinks indicating that it is the first digit to be 
changed. 

3. To change the value, press either Menu> or <Menu until the 
value you want is reached. Press Select to move to the next 
digit, or press Select again to skip a digit. Change each digit as 
required. When the last digit is changed, press Select to 

Diagnostic Aids 3-21 



4069-XXX 

validate the Configuration ID. If the ID is invalid then "INVALID 
ID" message displays on Line 2 before the ID redisplays. You 
have to reenter the Configuration ID until a valid ID is verified. If 
the ID is valid then the ID is saved in NVRAM and the printer 
automatically PORs to activate the new setting. 
Note: When the printer PORs it does so in the normal mode. 

Restore EP Factory Defaults 

To restore each of the printer settings contained in the EP Setup 
menu to their factory default value select Restore from the menu. To 
exit the menu without restoring the settings to the factory default 
values, select Do Not Restore. Sometimes this is used to help 
correct print quality problems. 

Fuser Temperature 

This adjustment can be used to help solve some customer problems 
with paper curl on low grade papers and or problems with letter 
heads on some types of media. 

The fuser temperature can be adjusted as follows: 

• NORMAL 

• LOWER 

• LOWEST 

Warm Up Time 

You can change the amount of time the printer warms up before 
allowing pages to print by changing this setting from to 5. The 
factory sets the warm up at or no warm up time. This time period 
allows the backup roll to heat up and helps reduce curl in some 
environments. 

Transfer 

The transfer can be adjusted as follows: 

• LOW 

• MEDIUM 

• HIGH 



3-22 Service Manual 



4069-XXX 
Print Contrast 

The print contrast setting controls the developer voltage offset. 

The print contrast can be adjusted as follows: 

• LOW 

• MEDIUM 

• HIGH 

Charge Roll 

The charge roll can be adjusted as follows: 

• LOW 

• MEDIUM 

• HIGH 

Print Tests 

The purpose of the diagnostic Print Tests is to verify that the printer 
can print on media from each of the installed input options. Each of 
the installed options is listed in the following order in the menu: 

Tray 1 

Tray 2 (if installed) 

Tray 3 (if installed) 

Tray 4 (if installed) 

Tray 5 (if installed) 

Multipurpose Feeder (if installed) 

Envelope Feeder (if installed) 

For each input source selected you have the following choice: 

• Single (prints the Print Test Page once) 

• Continuous (continue printing the Print Test Page until Return or 
Stop is pressed). 



Diagnostic Aids 3-23 



4069-XXX 

The contents of the Print Test Page varies depending on the media 
installed in the selected input source. 

Note: The Print Test Page always prints on one side of the paper, 
regardless of the duplex setting or the presence of a duplex option. 

If a source is selected that contains envelopes, an envelope test 
pattern is printed. If continuous is selected, the test pattern is printed 
only on the first envelope. 

To run the Print Test Page: 

1 . Select Print Tests from the Diagnostic menu. 

2. Select the media source. 

3. Select Single or Continuous. 

- If single is selected no buttons are active during printing. 

- If continuous is selected, Return or Stop can be selected to 
cancel the test. 

Check each Test Page from each source to assist in Print Quality 
and Paper Feed problems. 

Print Quality Test Pages 

The purpose of this diagnostic function is to allow printing of the print 
quality test pages with the toner cartridge lockout function disabled. 
The print quality test consists of three pages. Page one contains a 
mixture of graphics and text. Pages two and three only contain 
graphics. If duplex is turned On, the pages are duplexed, otherwise 
the pages are printed on one side. The Print Quality Test pages are 
printed in English and must always be printed on letter, legal or A4 
paper. 

Note: The print quality test pages can also be printed from the 
configuration menu, however a cartridge must be installed with a 
machine class ID matching the machine class ID stored in NVRAM. 
Some diagnostic information may be printed on the pages when 
printing from this menu. 



3-24 Service Manual 



4069-XXX 

To run the Print Quality Test Pages: 

1 . Turn the printer off. 

2. Press and hold Select and Return. 

3. Turn on the printer. 

4. Release the buttons once Performing the Self Test displays. 

5. The printer performs its normal POR cycle then print one copy 
of the Print Quality Test pages. If you want more than one copy, 
perform these steps again. 

The following is printed on page 1 . 

• Diagnostic EP Setup: 

- fuser temperature, warm up time, transfer, print contrast and 
charge roll settings. 

• Contents of the Diagnostic Error Log. 

• Printer configuration information: 

- printer serial number, controller code level, engine code 
level, operator panel code level, smart option code levels, 
font versions, and so on. 

• Values for the Quality Menu settings used to print the pages. 

Printing Menu Settings Page 

Note: This test page must be printed on letter, legal or A4 paper. 
To print the Menu Settings Page: 

1. Select the TESTS MENU. 

2. Select Print Menus from the TESTS MENU. 

The page contains the following information: 

• A list of all the printer settings contained in the control panel 
menus and their values. 

• A list of the installed options and features such as RAM memory 
SIMMs, optional input paper trays, envelope feeder, duplexer, 
output bins, flash or disk. 

• Printer information such as serial number, page count, installed 
RAM, engine code level, RIP code level, envelope feeder code 
level, tray 1-5 code levels, output bin 1-3 code levels, control 
panel code levels, font ROM version and SRAM availability. 

Diagnostic Aids 3-25 



4069-XXX 



Autocompensator Operation 

The autocompensator is a paper pick device that generates its own 
normal force. This force generation is inherent in the fundamental 
design of the pick arm. If light media is used, it picks very gently. If a 
heavy media is used, it picks very aggressively. No customer 
adjustments are necessary, therefore no special trays are needed for 
card stock or labels. 

The gearing in the arm is designed so the input torque from the 
motor produces a movement about the pivot of the arm. This 
movement produces a downward force at the pick rolls. The friction 
between the pick roll and the paper produces a frictional locking 
condition. If the paper is physically held and not allowed to feed, then 
the motor stalls. Slippage between the roll and the paper is 
theoretically impossible. When the motor is energized the pick rolls 
are driven down into the stack increasing the normal force and drive 
force until the bending strength of the paper is overcome and the 
paper bends and moves up the dam. Once this critical threshold is 
achieved the normal force remains at a level just high enough to 
reliably feed the paper. Rather than having a fixed spring force for 
feeding all weights of paper like the D-roll, this device has its own 
mechanical logic for producing only enough pick energy to feed a 
single sheet of paper regardless of its stiffness. 

High normal force is one of the most significant contributors to 
double feeding paper. The pick arm is counter balanced by an 
extension spring located on the pick arm to reduce weight in the rest 
state. This spring is factory set to exert no more than ten to fifteen 
grams on the stack. This is as light as can be realistically set and 
always guarantee there is some force to start the autocompensating 
phenomena. This spring is not to be considered an adjustment for 
feeding problems unless it is obvious that the pick arm cannot fall all 
the way down to the bottom of the tray or has come loose. 



3-26 Service Manual 



4069-XXX 

Poor gear efficiency can cause the arm to generate higher normal 
forces. If the pick assembly is noisy, replacement may be required. 

The arm must pivot freely through its full range of motion. On 500 
sheet trays there are wrap springs located on the pivot arbors of the 
arm. These springs aid to prevent the arm from bouncing. If the arm 
appears to be binding or sticky near the bottom of the tray these 
springs may be the problem. Reducing the tension on the 
counterbalance spring may be used as a temporary fix to get 
additional weight at bottom, until the pick assembly can be replaced. 
However, the counterbalance spring is not to be considered an 
adjustment for feeding problems. 



Autoconnect System, Paper Tray Options, 
Envelope Feeder and Output Expander 
Operations 

Electrical 

Autoconnect Cabling and Connectors 

The printer options make electrical connection automatically or 
autoconnects requiring no external cables when the option is 
mechanically installed under the printer. Communication between 
the option and the base printer stops when you remove an option 
located above or below the printer. The printer no longer recognizes 
the option and deletes associated messages. Each installed option 
below the base printer provides an electrical autoconnect to the 
option attached below it. The output expander option attached above 
the base printer provides power to the option above it. We do not 
recommend to attach or "Hot Plug" any options with the base printer 
power turned On. 



Diagnostic Aids 3-27 



4069-XXX 
Duplex Option 

The duplex option interface is a six pin autoconnector that provides a 
+24 V dc, +24 V dc return, serial interface transmit signal, serial 
interface receive signal and two ground pins. The duplex option 
receives the +24 V dc from the base printer for the duplex motors 
and also converts the voltage to +5 V dc for duplex electronics. 

Duplex chassis grounding is provided from the printer to the duplex 
option through a ground spring attached to the frame and base of 
the printer. The ground connection is automatically made when the 
option is installed below the printer. 

The paper input sensor is located in the rear of the duplex unit under 
the input paper guide. The rear cover open switch is located on the 
rear cover assembly. The paper exit sensor is located on the left 
frame assembly. The jam removal tray open switch is located at the 
end of the left frame assembly. There are no switches in the level 2 
duplex option. 

Option Microcode 

The options are "Smart Options" or options that have a system 
board. The option system board has a microprocessor that controls 
the option mechanism. A software architecture is provided that 
controls the option and communicates information such as paper 
path status, sensor or switch status, motor status and so on to the 
base printer. 



3-28 Service Manual 



4069-XXX 



Fuser Operation 

Hot Roll Fuser 

The hot roll fuser in the Optra T printer is made up of two primary 
assemblies. The first assembly is the top fuser cover which contains 
the thermistor/cable, thermal fuse, cable assembly, left and right 
lamp brackets and cover. This is a complete assembly and the parts 
cannot be individually replaced as in previous Lexmark laser 
printers. 

The thermal fuse (two fuses in series) protects the fuser assembly 
and surrounding parts from ignition in the event of a failure in the 
fuser control circuitry by opening the AC circuit to the lamp. The 
thermistor assembly is designed to keep the temperature of the 
fuser hot roll within a predetermined temperature by being in contact 
with the fuser hot roll and changes resistance as the temperature of 
the hot roll increases. The thermistor resistance changes from 
approximately 1 50K ohms to approximately 260K ohms as the 
temperature of the fuser hot roll increases. The thermistor is 
connected to the fuser control board connector J2-1 and J2-2 and 
from J2 to J1 -2 and J1 -3 on the fuser control board to J2-6 and J2-7 
on the engine board. J2-6 (TEMPIN+) and J2-7 (TEMPIN-) are 
connected to module PLCC U9. U9 monitors the change in 
thermistor resistance and sends a signal (H EATON) from J20-A25 
through the interconnect board to CN3-9 on the LVPS to signal the 
triac to turn the fuser lamp On or Off to maintain the correct fuser 
temperature. 

The voltage drop across the thermistor is proportional to the fuser 
temperature and varies from approximately 2.0 V dc (cold) to 2.3 V 
dc (warm during idle) to approximately 2.7 V dc during continuous 
printing. These voltages are assuming the fuser temperature is set 
to normal. The HEATON signal from CN3-9 varies from V dc (lamp 
On) to +5 V dc (lamp Off) and is connected to the cathode of an 
Opto triac to control the fuser lamp. The second part of the assembly 
is the fuser frame which contains the hot roll, backup roll, and 
associated parts as well as the paper exit guide assembly, narrow 
media sensor, fuser control board (which has the exit sensor 
mounted on the board) and the envelope conditioner solenoid. 



Diagnostic Aids 3-29 



4069-XXX 

Belt Fuser 

The belt fuser utilizes a ceramic heating element inside a 
cylindrically formed belt as the heating element of the fusing 
process. The contact area of the belt is heated to fusing 
temperature. The media passes between the belt and a back-up 
roller, fusing the image to the media. The media then passes on 
through the decurl rollers to the paper exit. 

Unlike the hot roll fuser, the belt fuser does not require detack 
fingers to remove the paper from the heated surface (belt). This is 
because the contact portion of the belt, which is cylindrically shaped, 
gives as the fusing process occurs. This flattens the belt contact 
surface. The result is a sharp detack angle between the belt and the 
exiting media. This eliminates the need for detack fingers. 

The flattening of the belt in combination with the reduced pressure 
between the belt and the back-up roller allows the belt fuser to print 
on many different types of media without requiring a solenoid 
(thumper) to keep the media from wrinkling. A specific type of media 
that is affected is an envelope. 

The time for the first copy to print is constant for the belt fuser no 
matter what state the machine is in, warm or cold. This is a result of 
the belt being able to reach fusing temperature very rapidly. This 
happens due to the small area that must be heated. The ceramic 
slab heats a small portion of the belt that is directly involved in the 
fusing process. This is in sharp contrast to the hot roll, which heats 
the entire roll to fusing temperature. 



3-30 Service Manual 



4069-XXX 



Paper Feed Jams 

Paper Jams - Base Printer 

Error Message 200 - Paper Jam - Remove Cartridge 

This message indicates that paper is jammed at the printer input 
sensor. This condition can be caused by the paper jamming prior to 
activating the input sensor flag, the sensor not detecting paper over 
the sensor or paper arriving at the sensor too late. 

Note: A defective engine board or printhead can also cause a 200- 
Paper Jam message to occur prior to the paper reaching the input 
sensor flag. This error can display due to a problem with the HSYSC 
signal to or in the printhead. Use the sub error code table to assist in 
isolating a 200 paper jam message. 

Error Message 201 - Paper Jam - Remove Cartridge 

This message indicates the paper is jammed between the printer's 
input and exit sensors. This condition can be caused by the paper 
exiting the input sensor too late or jamming in the fuser assembly 
prior to activating the exit sensor flag in time or not at all. 

Error Message 202 - Paper Jam - Open Rear Door 

This message indicates the paper is jammed at the printer exit 
sensor. This can be caused by the paper arriving at the sensor too 
late, the paper is jammed in the fuser assembly or is jammed exiting 
the fuser assembly in the redrive assembly or the exit sensor flag is 
not operating correctly. 

Paper Jams - Options 

Error Message 230 Paper Jam - Check Duplex 

The paper is most likely jammed in the duplex unit, however the 
paper can also be jammed in the redrive at the input to the duplex 
option. The redrive assembly may not be correctly installed or locked 
in position or the duplex link is bent and not aligned properly to allow 
paper to feed correctly into the duplex option. 



Diagnostic Aids 3-31 



4069-XXX 

Error Message 24x (x=Tray 1 through 5) Paper Jam Check Tray x. 

The paper has not cleared the pass through sensor or reached the 
pass through sensor of the option above tray x. 

Error Message 250 - Paper Jam - Check MP Feeder 

The paper is jammed in the multipurpose feeder and has not 
reached the base machine input sensor or has not reached the input 
sensor in time. 

Error Message 260 Paper Jam - Check Envelope Feeder 

An envelope is jammed in the envelope feeder or has not reached 
the base machine input sensor. 

Error Message 27x Paper Jam - Check Bin x. 

Paper is jammed in output bin x (X=bin 1 thru 3). Generally this 
message appears when the paper has not cleared the exit sensor in 
time, has jammed in the redrive assembly or has not fed into the 
output bin selected. 



3-32 Service Manual 



4069-XXX 



4. Repair Information 

WARNING: Read the following before handling electronic parts. 

Handling ESD-Sensitive Parts 

Many electronic products use parts that are known to be sensitive to 
electrostatic discharge (ESD). To prevent damage to ESD-sensitive 
parts, follow the instructions below in addition to all the usual 
precautions, such as turning off power before removing logic boards: 

• Keep the ESD-sensitive part in its original shipping container (a 
special "ESD bag") until you are ready to install the part into the 
machine. 

• Make the least-possible movements with your body to prevent 
an increase of static electricity from clothing fibers, carpets, and 
furniture. 

• Put the ESD wrist strap on your wrist. Connect the wrist band to 
the system ground point. This discharges any static electricity in 
your body to the machine. 

• Hold the ESD-sensitive part by its edge connector shroud 
(cover); do not touch its pins. If you are removing a pluggable 
module, use the correct tool. 

• Do not place the ESD-sensitive part on the machine cover or on 
a metal table; if you need to put down the ESD-sensitive part for 
any reason, first put it into its special bag. 

• Machine covers and metal tables are electrical grounds. They 
increase the risk of damage because they make a discharge 
path from your body through the ESD-sensitive part. (Large 
metal objects can be discharge paths without being grounded.) 

• Prevent ESD-sensitive parts from being accidentally touched by 
other personnel. Install machine covers when you are not 
working on the machine, and do not put unprotected ESD- 
sensitive parts on a table. 

• If possible, keep all ESD-sensitive parts in a grounded metal 
cabinet (case). 

• Be extra careful in working with ESD-sensitive parts when cold- 
weather heating is used because low humidity increases static 
electricity. 

Repair Information 4-1 



4069-XXX 



Adjustment Procedures 

Duplex Motor Drive Belts 

Do the duplex motor belt and drive belt adjustment whenever you 
remove or replace the duplex motor or loosen the motor or drive belt 
idler pulley. 

Service Tip: Excessive belt tension can result in stalling the duplex 
motor. Too little belt tension can result in belt slippage. 

To do the duplex drive belt adjustment: 

1 . Do the removal procedure "Duplex Front Cover Door" on 
page 4-19 to access the drive belt idler pulley. 

2. Loosen the idler pulley mounting screw and position the idler to 
provide 3 mm (±.5 mm) drive belt deflection. 

3. Tighten the idler pulley mounting screw being careful to 
maintain the adjustment. 

4. Reassemble the duplex unit. 

To do the duplex motor belt adjustment: 

1 . Do the removal procedure "Duplex Motor" on page 4-20 to 
access the motor mounting screws but do not remove the motor. 

2. Loosen the screw in the elongated adjustment slot and position 
the motor to provide 3 mm (±.5 mm) motor belt deflection. 

3. Tighten both mounting screws being careful to maintain the 
adjustment. 

4. Reassemble the duplex unit. 



4-2 Service Manual 



4069-XXX 

Fuser Solenoid Adjustment 

Perform the fuser solenoid adjustment whenever you replace the 
fuser solenoid. Adjust the fuser solenoid while installed in the printer. 
Adjust the screw on the eccentric mounted on the solenoid housing 
to provide an air gap between the rear of the solenoid stator and the 
solenoid armature. 



Printer Models 


Solenoid Air Gap 


01 0/21 2/01 n/21n 


4.0 mm 


41 4/61 6/41 n/61n 


4.5 mm 



Gap Adjustment 

The gap adjustment allows you to increase the minimum gap 
between sheets of paper as they are fed through the printer. This 
adjustment does not reduce the printer's overall performance such 
as pages per minute but can help in reducing the amount of curl of 
some printed media thus improving media stacking in the output bin. 

1 . Enter the Diagnostic Mode 

2. Select EP SETUP from the Diagnostic Menu. 

3. Select GAP ADJUST 

4. The range of the GAP adjustment is to 255. Adjust the gap 
setting by using the Menu < > button to select the value. If 
GAP=0 displays, it indicates a factory setting to minimum gap. 
Select a value and run several copies of the media that displays 
a curl problem. It may take several tries before improvement is 
noticed. 

Note: This setting has no effect when printing in duplex mode. 



Repair Information 4-3 



4069-XXX 

Printhead Assembly Adjustment 

Do the printhead assembly adjustment whenever you remove or 
replace the printhead assembly or loosen the mounting screws. 

Install the new printhead with the three mounting screws centered in 
the slots in the printhead frame assembly. Leave the screws loose 
enough to allow the printhead assembly to move from side to side 
within the slots. It is necessary to perform a registration adjustment 
before locking down the three printhead mounting screws. 

To perform the registration adjustment: 

1 . Turn the printer off. 

2. Press and hold: Return and Go. 

3. Turn the printer On and release the buttons when "Performing 
Self Test" displays. 

4. Select Registration from the menu. 

5. Select Quick Test Page. The test page should only be printed on 
letter or A4 paper from Tray 1 . The Quick Test Page consists of 
alignment diamonds, horizontal lines that can be used for skew 
adjustment, page count setting, printer serial number code 
levels and print registration settings. 

6. Check the Quick Test Page for any sign of skew by checking the 
diamonds at the top left and top right of the test page for equal 
distance from the top of the page. If any adjustment is 
necessary, adjust the left or right printhead mounting screws 
and check the skew again by running another Quick Test Page. 
This procedure may take two or three attempts before you get 
satisfactory results. 

7. When you have the correct adjustment, gently tighten the 
printhead mounting screws being careful not to move the 
printhead assembly. 



4-4 Service Manual 



4069-XXX 

Paper Alignment Assembly Adjustment 

Do the alignment assembly adjustment whenever you replace the 
alignment assembly. Always print a copy of the Quick Test Page 
before making any adjustments to the alignment assembly reference 
adjustment screw. When replacing the alignment assembly, it is 
necessary to back the reference adjustment screw out far enough to 
remove the old assembly and install the new one. 

If you are replacing the alignment assembly go to step a. If you are 
only adjusting the reference adjustment screw go to step b. 

a. Print a copy of the Quick Test Page and check the margin 
adjustments printed on the test page. These settings should 
be within the range specified in "Print Registration" on 
page 3-19. 

Do the reference adjustment if you are sure the margins are set 
correctly. 

1 . Loosen the locknut on the inside rear of the alignment 
assembly. 

2. Remove the two screws holding the alignment assembly to the 
left side frame. 

3. Back the reference adjustment screw out far enough to allow 
the alignment assembly to be removed from the printer. It is not 
necessary to completely remove the screw. 

4. Install the new alignment assembly. Turn the reference screw 
clockwise with a 7 mm nut driver until it touches the back of the 
reference plate and tighten the nut with a 5.5 mm wrench. 

The reference adjustment screw can be adjusted without loosening 
the nut. Turn the screw clockwise a few turns and print a copy of the 
Quick Test Page as you check the diamonds on the left margin. 
Continue adjusting the screw as you check the results of each 
adjustment on a new test page until you obtain the results you want. 



Repair Information 4-5 



4069-XXX 

b. 



Print a copy of the Quick Test Page and check the margin 
adjustments printed on the test page. These settings should 
be within the range specified in "Print Registration" on 
page 3-19. The reference screw can be adjusted without 
loosening the locknut. Turn the screw a few turns and print a 
copy of the Quick Test Page as you check the diamonds on 
the left margin. Continue adjusting the screw as you check 
the results of each adjustment on a new test page until you 
obtain the results you want. 




4-6 Service Manual 



4069-XXX 



Screw Identification Table 

The following table contains screw types, locations, and quantities 
necessary to service the printer. Each screw callout in the removal 
procedure graphic displays the screw reference number listed in the 
table. Pay careful attention to each screw type location when doing 
removals. You must install the correct screw type in each location 
during reassembly. 



Reference 
Number 


Screw Type 


Location 


Purpose 


Qty 


102 ^23 

If 


M3.5x8 mm 
Thread Cutting 


right side frame to 
center pan 


attach 


1 


toner level sensor 


mounting 


1 


charge roll 


mounting 


1 


main drive gearbox 


mounting 


3 


EP module to left and 
right side frame 


attach 


9 


developer drive 
assembly 


mounting 


2 


stacker duct to frame 


mounting 


2 


cartridge hold down 
assembly 


mounting 


2 


MPT deflector 


mounting 


2 


interconnect board 
shield ground 


attach 


2 


engine board shield to 
frame 


attach 


1 


laser cover 


mounting 


4 


deflector 


mounting 


2 



Repair Information 4-7 



4069-XXX 



Reference 
Number 


Screw Type 


Location 


Purpose 


Qty 


© 

102 e^ 


M3.5x8 mm 
Thread Cutting 


spring 


mounting 


1 


controller board 


mounting 
(front) 


2 


integrated tray ITC 
board 


mounting 


2 


stacker support to right 
side frame 


attach 


2 


104 e=3 

II 

T A 
T A 

y 


M3.5x12 mm 
Thread Cutting 


engine board shield to 
left frame 


attach 


1 


paper alignment 
assembly 


mounting 


2 


toner cartridge guide 
track 


mounting 


2 


left side frame to center 
pan 


attach 


3 


right side frame to 
center pan 


attach 


2 


deflector 


mounting 


2 


(§) 

201 e? 

o 


M3x5 mm 
Taptite 


I NA cover 

(2 screws per cover) 


attach 


6 


interconnect board 


mounting 


5 



4-8 Service Manual 



4069-XXX 



Reference 
Number 



Screw Type 



Location 



Purpose 



Qty 



M3x6 mm 
Taptite 



202 



outer shield 



mounting 



inner redrive deflector 



mounting 



interconnect board to 
center pan 



mounting 



engine board 
(bottom holes) 



mounting 



controller board to 
interconnect board 
ground 



attach 



controller board to inner 
shield 



mounting 



controller board (back) 



mounting 



engine board to 
interconnect shield 
ground 



attach 



lower stacker duct 



mounting 



ground cables to ground 
(center pan - front) 



attach 



cable clip (main drive 
gearbox, BTM) 



mounting 



fuser screw 



mounting 



M3x8 mm 
Taptite 



203 



LVPS 



mounting 



auto compensator 
hanger bracket 



mounting 



Repair Information 4-9 



4069-XXX 



Reference 
Number 



Screw Type 



Location 



Purpose 



Qty 



235 



M3x12 mm 

Taptite 

Panhead 



HVPS board 



mounting 



237 B 



M3x28 mm 

Taptite 

Panhead 



developer drive ground 
(bottom hole) 



attach 



232 



M3x6 mm 

Taptite 

Panhead 



stacker duct 



engine board 



controller to shield 



controller board 



in pan 



shield ground 



LVPS 



fuser cover 



cable clip 



outer shield 



ma cover 



mounting 



mounting 



mounting 



mounting 



mounting 



attach 



mounting 



mounting 



mounting 



mounting 



mounting 



4-10 Service Manual 



4069-XXX 



Reference 
Number 



Screw Type 



Location 



Purpose 



Qty 



M3.5x8 mm 
Plastite Thread 
Forming 



autocompensator 



mounting 



323 £3 



Xs3 



M3.5x10 mm 
Plastite Thread 
Forming 



right side cover 



mounting 



right side frame to pan 



attach 



324 e^ 



left side frame to pan 



attach 



M3x6 mm 
SEMS Machine 
Screw with 
washer 



fuser board 



mounting 



397 < i 




M3.5x12 mm 
Plastite Thread 
Forming with 
washer 



printhead to EP frame 



mounting 



425 r=3 



V J, 



ik? 



Repair Information 4-11 



4069-XXX 



Removal Procedures 

CAUTION: Remove the power cord from the printer or wall outlet 
before you connect or disconnect any cable or electronic board or 
assembly for personal safety and to prevent damage to the printer. 
Use the hand grips on the side of the printer. Make sure your fingers 
are not under the printer when you lift or set the printer down. 

Note: Some removal procedures require removing cable ties. You 
must replace cable ties during reassembly to avoid pinching wires, 
obstructing the paper path, or restricting mechanical movement. 

Covers 

Left Door 

1 . Open the upper and bottom front covers. 

1 . Press the two left door latch buttons (A) and open the left door. 

2. Release the left door from the rear hinges and remove the door. 




4-12 Service Manual 



4069-XXX 
Right Cover 

1 . Open the upper and bottom front covers. 

2. Release the cover latch (A) and remove the right cover 
mounting screw (B). 

B (324) 




Repair Information 4-13 



4069-XXX 

3. Remove the redrive assembly. 

4. Remove the right side cover mounting screw (B). 

5. Remove the right side cover. 

B (324) 




4-14 Service Manual 



4069-XXX 

Upper Front Cover 

1 . Raise the upper front cover. 

2. Remove the upper front cover mounting screws (A). 

3. Rotate the cover upward to allow the rear cover hinges to clear 
the mounting slots and remove the cover. 

A (323) 




Repair Information 4-15 



4069-XXX 

Laser Assembly Cover 

1 . Remove the left door. 

2. Remove the right cover. 

3. Remove the rear paper deflector. 

4. Press the fuser wiper cover latch and remove the cover. 

5. Remove the paper full sensor flag assembly from the mounting 
bracket. 

6. Remove the mounting screws (A) and remove the cover. 

A (102) 




A (102) 



A (102) 



Center Pan Assembly 

1 . Remove the left and right side frames. 

2. Remove the pan assembly. 



4-16 Service Manual 



4069-XXX 

Controller Board 

1. Remove the inner EMC shield. 

2. Remove the controller board mounting screw (A). 

3. Remove the controller board mounting screws (C). 

4. Remove the controller board parallel port mounting screws (B). 

5. Remove the serial port mounting screws if present. 

6. Remove the controller board. 




•C (102) 



Repair Information 4-17